SPEA for BeFC: Flying Probe Testing of Paper-Based Biofuel Cells

SPEA Flying Probe Tester - Testing BeFC Paper Biofuel Cells

In a world demanding ever more portable, connected, and disposable electronics, the need for sustainable low-energy power sources has never been greater. Traditional lithium coin and button batteries, though widely used in a vast array of low-power consumption devices, are increasingly criticized for their substantial environmental footprint, elevated costs, and limited long-term sustainability.

Stepping away from this cycle, companies like BeFC are leading a revolution with eco-friendly, low-energy power sources that directly addresses a critical environmental problem of nearly 15 billion disposable coin batteries thrown away each year. Their breakthrough: paper-based biofuel cells capable of powering modern electronics in a greener way.

The Bio-Science Behind BeFC’s Metal-Free Power Source

Founded in 2020, BeFC stands at the forefront of deep-tech innovations, intent on replacing conventional toxic miniature batteries with an electronic assembly built on natural principles.

Unlike conventional batteries built with rare metals and harsh chemicals, BeFC paper-based biofuel cells use biological catalysts to generate energy from natural reactants like glucose and oxygen. The core structure utilizes a paper sheet to act as the primary structure for the biofuel cell elements and as the substrate for the printed electronics, making the device ultra-thin, flexible, and fundamentally easily recyclable. The biological catalysts, specifically enzymes, are printed into the paper to facilitate energy conversion. The system is fueled by abundant, natural substrates: the primary fuel is glucose, which is converted to electricity using oxygen from the air. When a liquid, such as environmental water or a biological fluid, is introduced, the cell is activated, triggering an electrochemical reaction between the enzymes, sugar, and oxygen to generate a clean, metal-free flow of energy. Ultimately, this organic composition ensures the power source is not only efficient for low-power electronics but also entirely sustainable and safe for high-volume use.

This innovative approach draws upon more than twenty years of dedicated research, initially aimed at powering life-saving implantable medical devices such as pacemakers using endogenous metabolic sources.

Today, this robust scientific foundation supports BeFC transition from laboratory to a production of thousands units of ultra-thin paper-based flexible printed circuit boards integrating biofuel cell technology, powering low-energy devices like MEMS sensors, wireless protocols, and storage solutions. These include advanced biomedical sensors designed for continuous patient health monitoring and wearable diagnostics in healthcare; smart tracking and authentication tags in complex logistics networks; and intelligent packaging systems equipped with environmental sensors.

The Critical Challenges of Testing Ultra-Thin Paper-Based Circuits

As innovation propels the industry, the critical question becomes: how can such technologies be reliably tested to ensure quality and function?

Undoubtedly, scaling BeFC innovative power cell technology into high quality production presents unique challenges, especially when it comes to verifying the integrity and functionality of the ultra-thin flexible paper-based printed circuit boards and assembled devices of 1 cm2 that are only a few hundred microns in a wide range of sizes and formats.

“The use of paper substrates introduces unique quality control challenges that traditional testing methods simply cannot address” – explains Mr. Alban Thierry, Firmware Lead at BeFC- “The substrate is much thinner and more fragile than standard 1.6 mm thick boards, making it prone to tearing and deformation when testing. We needed to overcome the testing challenges connected to the substrate as well as moving away from risking damage to the cells or failing to provide reliable verification”.

To overcome these challenges, BeFC completely redesigned its testing strategy. Traditional manual inspections, while valuable for many applications, can be time-intensive and occasionally limited in detecting all defects, while conventional bed-of-nails testing methods have proved to be unsuitable for the high-tech paper circuits. This drove the investment in automatic solutions capable of detecting the tiniest shorts and opens while treating the delicate thin circuits with the utmost care.

How Flying Probe Testing Empowers BeFC Innovation

Capable of combining the advantages of automatic testing tailored to the specific needs of electronic manufacturers with deep expertise in test equipment design, SPEA, leader in automatic test equipment, has played a crucial role for BeFC.

Leveraging this unique combination, SPEA has seamlessly integrated its flying probe tester technology into BeFC’s testing workflow, ensuring highly reliable verification for their innovative products.

The SPEA flying probe tester represents a cutting-edge testing technology widely embraced in contemporary electronics manufacturing for both prototyping and production. In contrast to traditional testing methods that rely on fixed fixtures or “bed-of-nails” test jigs, flying probe testers use multiple precision-controlled probes mounted on robotic arms to make direct contact with specific test points on the circuit board. This agile probing method enables comprehensive electrical evaluations, including continuity checks, detection of shorts, and precise measurement of component values, all accomplished while minimizing mechanical impact thanks to SPEA’s patented ultra-soft-touch probes.

Moreover, the flying probe tester operates with exceptional flexibility, guided by programmatic test patterns derived from detailed board design files. This adaptability allows for rapid, cost-effective reprogramming whenever new board layouts are introduced, an essential feature for BeFC’s dynamic testing environment. Beyond static electrical checks, SPEA’s tester supports functional test sequences, incorporating in-system programming of embedded microcontrollers. This dual capability not only verifies quality but also streamlines the manufacturing workflow by programming the boards during the testing phase, significantly reducing production times and enhancing operational efficiency.

To address the delicate nature of BeFC’s innovative circuits, SPEA developed a customized handling system and support tailored specifically to maintain paper circuit stability during testing with the flying probe equipment. Additionally, the tester’s ultra-soft-touch technology ensures test probes apply minimal pressure, protecting the delicate circuits from damage. The flexibility of the SPEA flying probe tester is particularly valuable for BeFC high-mix prototyping and production: “The flexibility of the flying probe tester is critical to our processes, allowing us to test multiple designs without the expense or delay of new tooling. The SPEA software is intuitive and fast to learn, making it easy to integrate new designs seamlessly and the built-in maintenance features help us keep performance optimal,” concludes Mr. Alban Thierry.

Full-Scale Production with Robust Quality Practices

BeFC stands at the forefront of innovation in sustainable low-energy power sources, pioneering organic, paper-based biofuel cells that redefine how electronics can be powered responsibly.
The transformation of chemical energy into sustainable electrical power defines BeFC’s approach, demonstrating how revolutionary materials science drives the new frontier of electronic design.
“Sustainability is becoming a new criteria for the evaluation of electronic products. BeFC is addressing this first, with its revolutionary metal-free bio-based energy solution, but also through the hardware & firmware design of its electronic platforms, including the exploitation of ASICs and printed electronics.”- explains Mr. Jules Hammond, CTO at BeFC.

As the company moves beyond prototyping toward full-scale production, the demands for thorough quality assurance significantly increase.

“We aim to use the flying probe tester for a function that extends far beyond simple quality control. Our goal is to integrate In-System Programming (ISP) directly into the testing cycle. We plan to use the SPEA flying probe tester not only for ICT testing but also to flash the board, putting the final code inside the microcontrollers. This process is critical for writing specific data, such as unique IDs and essential initialization parameters.” reveals Mr. Alban Thierry.
By doing this, BeFC transforms the flying probe tester from a verification tool into a comprehensive quality assurance station, streamlining different manufacturing steps into one automatic sequence, as Mr. Jules Hammond highlights: “With the flying probe test and programming equipment from SPEA, we can fast-track R&D efforts, whilst also providing a route to scale production in the future.”

The collaboration between BeFC and SPEA signals a significant step forward, showing how sustainable low-energy power, supported by cutting-edge testing technology and industry-leading expertise, can redefine the future of environmentally conscious electronics.