Suryudey pioneers functional printing for smart textiles, printing conductive circuits at 50 microns

INDIA – Pune-based startup Suryudey Plastic Electronics has leveraged advanced screen-printing techniques to produce flexible electronics, printing silver-carbon conductive inks onto TPU substrates for heated jackets, medical biosensors, and defense textiles.

Unlike traditional heated garments that rely on bulky copper wiring or fragile carbon fibres, Suryudey screen-prints resistive heating elements directly onto thermoplastic polyurethane substrates. 

The resulting circuits are approximately 50 micrometres thick, roughly half the diameter of a human hair, and can be hot-laminated onto fabrics, remaining flexible, breathable, and durable enough to withstand daily wear and washing, with uniform heat distribution via integrated NTC thermistors.

A Dual-Brand Strategy

The company has bifurcated its technology into two distinct market streams. 

Iðoona is a consumer-facing brand offering lightweight heated jackets, vests, and gloves powered by standard USB-C power banks. 

SPEZL is a specialised B2B division focused on functional printing for high-stakes industries, including medical biosensors and defense applications. 

Through the Innovations for Defence Excellence (iDEX) initiative, Suryudey is developing connected textiles for the Indian military, including garments with integrated antennas and health-monitoring sensors.

The Technology Behind the Print

Screen printing for functional electronics differs fundamentally from decorative printing. Conductive inks must maintain consistent resistivity after curing, adhere to flexible substrates without cracking, and survive repeated flexing and washing. 

Suryudey’s proprietary silver-carbon formulations address these requirements while keeping production costs low enough for commercial viability. 

The 50-micron thickness allows the printed circuits to sit almost invisibly within garment layers.

Scaling “Make in India” Innovation

With its manufacturing base in Pune, Suryudey is a prime example of the “Make in India” movement in the electronics sector. 

By localising production of functional inks and flexible substrates, the company reduces reliance on imported components while pushing the boundaries of what screen printing can achieve. 

The global smart textiles market is projected to grow from approximately US$5 billion in 2024 to over US$15 billion by 2032.

When Printing Powers the Jacket

A printed circuit that heats a jacket without restricting movement is not a novelty, it is a new category. 

Suryudey’s screen-printed electronics prove that the same technology used to print t-shirts can now print wearable warmth. For the printing industry, that is not an evolution; it is a reinvention.

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