High speed replication of nanostructures on plastic foil

What is it about?

A novel high speed roll-to-roll process for nano- and microstructuring of large areas of plastic foils. Replication of nanostructures with size below 100 nm was demonstrated at line-speed of 60 meters per minute. The process is known as roll-to-roll extrusion coating (in the packaging industry commonly referred to as co-extrusion), and is widely used for production of smooth polymer films, but has not previously been employed for replication of nanostructures. In roll-to-roll extrusion coating a molten polymer film is extruded through a flat nozzle forming a melt curtain, then stretched in air, and finally laminated onto a carrier foil. The lamination process takes place as the melt curtain is squeezed between a cooling roller and a rubber counter roller. By attaching a nanostructured metal sheet to the surface of the cooling roller, the relief structure from the sheet can be replicated onto a plastic foil.

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Why is it important?

The process has potential to accelerate the integration of nanostructured materials in a broad range of applications, including optical, technical and functional surfaces and devices.

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