Printed Electronics & Flexible Hybrid Electronics worked example

Substrate Usage at 99% target substrate utilization: a worked example

This scenario runs the substrate usage calculation on the strong side: 99% target substrate utilization, with every other input held at its documented default. Use it when substrate usage in printed electronics and flexible hybrid electronics needs a clean rate and gap-to-target you can put on a tier board.

The inputs for this scenario

  • Substrate area used for good circuits: 8 units (unchanged)
  • Total substrate area consumed: 250 units (unchanged)
  • Target substrate utilization: 99 % (raised for this scenario; the documented default is 95)

Working through the calculation

  • Applying the documented formula (Substrate Usage rate = affected amount รท total amount) to the inputs above produces each figure below.
  • At this operating point the engine returns 3.2 % for rate, the number this scenario is built around.
  • At this operating point the engine returns 95.8 points for gap to target.
  • At this operating point the engine returns 8 count for affected count.
  • At this operating point the engine returns 250 count for total count.

How this compares with the baseline

  • Against the tool's baseline example, where target substrate utilization sits at 95% and the headline result is 3.2 %, this scenario lands almost exactly on the baseline at 3.2 %.
  • Use it after a run or campaign to quantify material efficiency and justify better nesting, narrower margins, or reduced changeover waste. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Rate: 3.2 % (headline result)
  • Gap to target: 95.8 points
  • Affected count: 8 count
  • Total count: 250 count

Run it with your numbers

  • Every input above is editable in the live Substrate Usage calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.