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Roll-to-Roll

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    PRODUCT:

    Component or system, which is commercialized. It is available for ordering multiple pieces and liability is assumed by the provider/seller. Necessary certification of the product was obtained (e.g. CE certification). The product sheet and/or conditions of use are defined.

    PROTOTYPE:

    Component or system, which has been successfully tested under real or real-like conditions. The prototype is not commercialized as the main purpose is to use it for demonstration and experimentation, including user and market acceptance.

    TECHNICAL SERVICE:

    Tools and processes and its combination, which are necessary to prepare and test prototypes or products.
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  • Market
    • Lighting
    • Optical instrumentation
  • Manufacturing Pillar
    • Roll-2-Roll
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JOANNEUM RESEARCH offers Roll-to-Roll (R2R) manufacturing for optical, optoelectronic, and electronic components. This process enables mass production of micro- and nanostructures on flexible substrates, with tailored UV resin properties. It supports sustainable, cost-effective product development in biotechnology, nanotechnology, and advanced manufacturing.

Offering Description

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.

Offering Specifications

  • 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

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