JOANNEUM RESEARCH Forschungsgesellschaft mbH
[REPLICATION] master scale-up [OTHER] Other
Lighting Optical instrumentation

We have been involved in the development of manufacturing processes for optical, optoelectronic and electronic components for more than 10 years. The established knowledge in design, fabrication, characterization and optimization is now available to industry in combination with the roll-to-roll pilot line for the development of sustainable industry compatible manufacturing processes.

The utilization of roll-based imprinting processes enables the mass fabrication of micro- and nanostructures on large and flexible substrate materials. These can be used in optical, electronic, sensory or bionic applications. Roll-to-roll micro- and nanostructuring thus forms the basis for the development of novel and cost effective products in Key Enabling Technology fields such as biotechnology, nanotechnology, as well as advanced materials or advanced manufacturing and production tech-nologies.

This continuous roll-to-roll process relies on a number of steps: (i) After unwinding, a flexible plastic film (acting as a substrate) is coated with a UV curable resin. Our NILcure® imprint resin portfolio offers a wide range of possibilities and the resin can be tailored in terms of mechanical, chemical and optical properties. (ii) The coated substrate is then guided to the imprinting station, where a stamp with the desired surface pattern is pressed into the liquid resin. The stamp is usually a nickel or polymer sheet with excellent anti-sticking properties which is wrapped around the imprinting roller. (iii) While in contact with the stamp the resin is solidified by UV light and afterwards the imprint is demolded and wound up.

  • Resist coating by means of gravure printing or slot die coating:
    • Coating thickness range: 200nm - 200 μm
  • UV imprinting and hot embossing
    • UV LED irradiance: max. 14W/cm², 365 or 395
    • Mercury vapor lamp: max. 18 W/cm², broadband
    • Line pressure UV imprinting: max. 60 kN/m
    • Line pressure hot embossing: max. 330 kN/m
  • Lamination
    • UV lamination
  • Substrate
    • Transparent films: width 250 mm
  • Throughput
    • Web speed: 0.5 - 30 m/min
  • Pre-treatment
    • Corona: max. 1000 W
  • In-line characterisatio