Human-Machine Interfaces (HMIs) have evolved significantly from what were once static control panels and rigid screens.

As devices become smarter, more compact, and more connected, users now expect interfaces that go beyond function to integrate seamlessly into a product's experience.

This shift has led to a growing demand for flexible and transparent displays, employing technologies that enable thinner, lighter, and more versatile designs. From automotive dashboards and medical devices to consumer wearables and industrial IoT systems, these next-generation displays are redefining how people interact with machines.

Driving this transformation are advanced Electronics Manufacturing Services (EMS) providers like PCI, who combine materials innovation, precision PCBA manufacturing, and scalable production expertise to bring these modern HMI concepts to life.

What Are Flexible and Transparent Displays?

Flexible displays are cutting-edge screens built on bendable substrates such as plastic or ultra-thin flexible glass. Unlike standard rigid or flat panels, these displays can curve, fold, or flex without compromising performance, offering new possibilities in product design and portability.

Meanwhile, transparent displays can transmit light through the screen, allowing users to view digital content while still seeing the objects behind it. This “see-through” feature enables immersive visual experiences and innovative interface designs that merge seamlessly with their surroundings.

Compared to traditional LCD or OLED panels, flexible and transparent displays have the advantage of being:

• Lighter
• Thinner
• More durable
• And offering greater design freedom.

These displays make it possible to create sleeker and highly integrated device architecture, while also reducing the risk of mechanical failure due to impact or vibration.

Flexible and transparent screens have applications that span multiple industries:

• Automotive: Curved dashboards and head-up displays (HUDs) that enhance driver visibility and aesthetics.
• Healthcare: Lightweight, wearable monitors and transparent diagnostic screens for continuous, real-time patient tracking.
• Industrial IoT: Smart control panels that integrate directly into machinery or equipment surfaces, saving space and improving usability.
• Consumer Electronics: Foldable smartphones, augmented reality (AR) glasses, and smart home appliances with adaptive display surfaces.

Together, these technologies represent the next stage in Human–Machine Interface (HMI) design, as they blend functionality, aesthetics, and intelligence into user interaction.

Flexible and Transparent Displays: Market Drivers and Adoption Trends

The demand for smarter, more immersive interfaces is driving global interest in flexible and transparent displays.

The market size for transparent displays is predicted to reach USD 56.17 billion by 2032 and grow at a rate of 41.89% from 2024 to 2032. The U.S. market, in particular, is witnessing tremendous demand driven by sectors like the military, retail, and healthcare.

In the consumer electronics world, the demand for immersive user experiences, including foldable smartphones and augmented reality (AR) glasses, is pushing electronics manufacturers to redefine how displays are shaped, embedded, and controlled. Consumers no longer view the screen as just a static component but as an essential part of the product’s identity, appeal, and functionality.

In industrial and IoT applications, flexible and transparent displays enable rugged yet compact HMI systems, ideal for environments where space and durability are a concern. These include applications such as factory control panels, logistics equipment, and field instruments. These displays and their resilience to vibration and impact also make them well-suited for outdoor or mobile use cases.

Additionally, technological advances in OLED, microLED, and flexible touch sensor integration are further accelerating adoption. These technologies deliver higher brightness, lower power consumption, and improved visibility under varying conditions, making them highly beneficial for wearable or mission-critical technologies.

The market for flexible and transparent displays is projected to expand over the coming years, prompted by developments in technology that include component miniaturisation, materials innovation, and the maturing of large-scale manufacturing processes.

Engineering and Manufacturing Challenges for Flexible and Transparent Displays

While these advanced displays promise new design possibilities, manufacturing them at scale can be a highly complex process. Unlike standard rigid panels, these displays must maintain electrical performance and optical integrity even under continuous bending, folding, or stress.

Some of the key technical challenges include:

• 1. Maintaining electrical performance during bending and flexing

Flexible and foldable displays rely on ultra-thin conductive layers and interconnects that must remain stable even when the screen bends or twists repeatedly.

Mechanical stress can easily cause microcracks or signal interruptions if the material composition or circuit design is not optimised. To achieve long-term reliability, precise control of materials, layer thickness, and trace routing is essential.

• 2. Ensuring adhesion and durability in multilayer structures

Flexible or transparent displays are composed of multiple stacked layers, including substrates, conductive inks, adhesives, and encapsulants, each with unique material properties.

Differences in thickness or thermal expansion can cause delamination or warping under heat and pressure. To ensure that these layers stay bonded over long-term use, robust adhesion processes, material compatibility validation, and accelerated life testing are crucial.

• 3. Managing yield, heat dissipation, and testing accuracy

Because flexible and transparent displays continue to shrink in thickness and increase in pixel density, even minor process variations can result in defects or uneven performance.

Electronics manufacturing teams must maintain tight control over parameters such as alignment, bonding temperature, and curing time. Effective thermal management and precise electrical testing ensure that every panel performs consistently while preventing overheating or degradation, steps which allow for scaling production without compromising quality or yield.

This is where EMS providers like PCI play an invaluable role. With deep expertise in advanced material handling, process engineering, and quality assurance, PCI can help bridge the gap between concept and commercial production.

PCI's capabilities include:

• Material selection and validation - Identifying substrates, adhesives, and coatings optimised for flexibility, transparency, and reliability.
• Flexible PCB assembly - Integrating ultra-thin circuit layers while ensuring mechanical stability and consistent electrical pathways.
• Precision bonding and encapsulation - Using controlled-environment processes to protect sensitive display layers from moisture, contaminants, and mechanical stress.
• Testing and calibration at micro-scale tolerances - Leveraging automated optical and electrical testing to ensure uniformity, performance, and long-term durability.

Through these capabilities, PCI helps customers translate innovative display designs into manufacturable products, supporting faster time-to-market and consistent quality at scale.

EMS Innovation: How PCI Supports Next-Gen Display Manufacturing

Building the next generation of HMI technology requires precision, agility, and deep manufacturing expertise, all core strengths of PCI. As flexible and transparent displays become ever more widely adopted, PCI helps clients bridge the gap between design ambition and production reality through innovation-driven electronics manufacturing solutions.

Advanced PCBA manufacturing and rapid prototyping for flexible circuits

PCI's advanced PCBA capabilities are equipped to handle ultra-thin substrates and flexible printed circuits (FPCs) that form the backbone of modern display assemblies. Through rapid prototyping, PCI enables early validation of form factors, flex performance, and signal integrity.

High-precision assembly for thin and transparent components

Working with transparent and speciality optical layers demands micro-level precision. PCI's automated assembly lines integrate high-resolution placement, optical inspection, and controlled bonding environments to ensure accuracy and quality across each unit.

Collaborative engineering to optimise manufacturability and performance

From the earliest design stages, PCI's engineering teams collaborate closely with clients to optimise a product's design and manufacturing considerations. Principles like Design for Manufacturing (DFM) and Design for Testing (DFT) are embedded throughout the process, ensuring attention to detail and resource-optimising steps at every stage.

Supply chain resilience for sourcing new materials and emerging components

Innovating in flexible and transparent display technology also calls for navigating a rapidly evolving component ecosystem. PCI leverages robust supplier partnerships and data-driven sourcing tools to secure the necessary materials and ensure component availability and long-term scalability even in unpredictable markets.

Commitment to continuous innovation

At the core of PCI's philosophy is a deep commitment to innovation. By investing in advanced process automation, material science expertise, and real-time data analytics, PCI ensures that clients are always ready to deliver the next wave of intelligent user experiences in HMI, across automotive, healthcare, industrial, and consumer sectors alike.

Shape the Future of HMI in Electronics Manufacturing with PCI

Flexible and transparent displays are constantly evolving and changing expectations in product design, user experience, and human–machine interaction. From foldable devices and curved dashboards to smart industrial panels, these technologies enable new levels of creativity, functionality, and engagement across industries.

As a trusted electronics manufacturing services (EMS) partner, PCI empowers innovators to turn these possibilities into reality. Through deep engineering expertise, advanced PCBA manufacturing, and end-to-end production excellence, PCI supports clients from concept to mass production. We help guarantee that every product meets the highest standards of quality, precision, and reliability in your sector.

Partner with PCI today to design, prototype, and manufacture future-ready flexible and transparent display solutions in HMI