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Large Scope High Precision UVLED Nanoimprint Replication System

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Large Scope High Precision UVLED Nanoimprint Replication System
Abstract:
Nanofabrication is the essential bridge between the discoveries of the nanoscience and real-world
nanotechnology products. Roll-to-roll processing is the most important step for expanding the
nanotechnology into a broad range of marketing applications, including flexible printed electronics
industry. Most original nanostructured substrate (Called as Master) is created by the lithography
mastering system. Due to the production cost and technology limited, the size of the these mastes
are limited, means it cannot be directly used for the commercial roll-to-roll nanofabrication
machine for the large scale production. Our object is to build up a larger scope replication machine
to create a bigger size working master by using nanoimprint technology and our know-how on UV
LED curing technology.
1.Excellence
Roll-to-roll nanofabrication process is limited by large size working substrate(shim). Project
LSHPNRS will design and demonstrate a high-precision UV LED replication system for creating
nanostructure on the large scope substrate by using Nanoimprint technology. This system also
creates a new cost-effectiveness value chain for EU stakeholders by maximizing nanofabrication
productivity and minimizing nanostructure attenuation during roll-to-roll process.
1.1Objectives
Objective 1. Demonstrate a high-precision replication system to achieve a nanostructured substrate
at 300x300 mm by using PMDS stamp with inside LED curing light.
Object 2. Create new business opportunities and jobs in European graphic printing industry by
upgrading their existing equipment and expanding added-value products in the fast-growing flexible
printed electronics market
1.2Concept and methodology
a) Concept
What is the problem in the market now?
Nanofabrication is the essential bridge between the discoveries of the nanoscience and real-
world nanotechnology products. Roll-to-roll processing is the most important step for expanding the
nanotechnology into a broad range of market applications, including flexible printed electronics
industry. Most original nanostructured substrate (Master) is created by the lithography mastering
system. Due to the production cost and technology limited, the size of these master is limited,
means it cannot be directly used for the commercial Roll-to-roll nanofabrication machines for the
large scale production. For example, a nanofabrication machine for optical diffusion film is at 800-
1000 mm width, while a master size is typically at 50x50 mm after the first replication by the
mastering company. To solve this problem, we need to replicate those masters to a working
substrate (shim) at a bigger size.
The most replication systems in the market are using photosensitive or ultraviolet light (UV)
method. The basic principle for both methods is using the nanostructures master as a moving stamp
to replicate the nanostructure on the new bigger size substrate. The attenuation of the nanostructures
during the photosensitive replication is better by using a metal stamp. The joints between the unit
plates are relatively larger by using higher stamping pressure during the replication process. Both
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methods face the problem when the photosensitive/UV curable glue overflow and destroy the
nanostructure during the processing.
Figure 1. Joints between the unit plates through
microscope
What is our idea?
Use Nanoimprint technology and a PMDS made stamp with inside UV LED curing light.
b) Methodology
UV LED Nanoimprint replication machine is on the base of nanoimprint technology with high
accuracy position control system, as a method of producing high fidelity replication of
nanostructure on the new substrate, including a die head at 50x50 mm, an object substrate size is
300x300 mm, a high precision workbench with moving position accuracy at +/-25 mic on both X
and Y direction.
The principle of Nanoimprint is like stamping. A die head with the nanostructured template is
pressed with controlled pressure on a substrate coated with a UV curable lacquer. Turn on the UV
LED light to cure this lacquer and lift up the die head. After the removal of the head, an inverse
reproduction of the characteristic will then be directly imprinted on the above substrate. The die
head automatically moves to the next position which is designed on the program and repeat the
above processing until the nanostructured image is overall of the object substrate.
Figure 2: Roll-to-Roll UV Nanoimprint Lithography for Large-Area Nano- and Micro-Structuring
of Flexible Substrates [1]
How Does Nanoimprint Replication System Work?
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Figure 3. UV LED NANOIMPRINT REPLICATION SYSTEM
Step1: We will build up a nanostructured template made by PDMS at 200-250mic with the reverse
nanostructure as the original template by applying liquid PDMS on the surface of the original
master.
Step2: A die head with the inside UV LED light source: To get better replication result, the UV
LED light source have a focus curing area at 50x50 mm according to the template size.
Figure 4. Die head side-view
Step3: Build up the high precision workbench with moving position accuracy at +/-25 mic on both
X and Y direction
Figure 5 High precision workbench with linear moving
DPL
Automatic
Replication
System
Die Head Work benc h Integrated PLC
Control system
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Step 4: An integrated control system to control the light intensity, position, pressure and speed.
2.Impact
2.1 Expected impact
Impact 1: Integrate nanoscale building blocks into complex, large scale systems that will become
the basis for a new European high-value industry by creating a new cross-sector interconnection
between nanoscience and graphic printing industry.
According to the marketing research, [2] global printing markets are changing, many publishing
products have electronic versions replacing previously printed volumes. E-books, on-line
newspaper and magazines are taking significant sections of their respective markets, while
directories, catalogues and brochures have electronic alternatives, more transactions are electronic
reducing demand for currency and cheques and advertising spend is moving into new areas
including on-line. These factors, alongside the continued growth of social networking, result in
declining volumes of many print products, but not packaging and labels where demand is growing.
For example, anti-counterfeit packaging market size will grow from USD 105.9 billion in 2018 to
USD 182.2 billion by 2023, at a CAGR of 11.5%. The anti-counterfeit packaging market is
projected to witness a high growth due to the increasing focus of manufacturers on brand protection
to reduce counterfeiting. [3] The most anti-counterfeit products use the technology of RFID,
Barcode, Hologram, Tangents. Our replication system provides a possibility to the traditional
printing companies entry the new fast-growing market by adding extra UV LED nanoimprint or
micro-embossing unit on their existing machines.
Impact 2: Strengthen technology take-up across Europe by creating a new effective-cost value
chain by maximizing roll-to-roll nanofabrication size and minimizing attenuation.
Most nanofabrication also uses nanoimprint technology to save the production cost. But the
lifetime of working shim is limited due to nanostructure continuous attenuation during the process,
especially when the nanostructured stamp is made by UV curable lacquer. Our replication system
uses a high solution nanostructured PDMS template to replicate nanostructured on the object
substrate, means the lifetime of template will be longer and the final replication result is better.
Figure 6 Joints between the unit plates through microscope done by UV nanoimprint replication
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Impact 3: Economic impact by helping the European and other stakeholders to get more profit from
productivity increasing and capacity expanding.
Large scope replication from the original master to a bigger size working substrate (shim) is a
key to increase Roll-to-roll nanofabrication productivity. Our project provides the possibility to the
stakeholders to maximizing their nanofabrication productivity.
Impact 4: Social impacts by creating more business and job opportunities in the graphic industry
by expanding the scope of products application on their existing equipment.
2.2 Measures to maximise impact
a. Dissemination and exploitation of result
• Internal dissemination: The internal dissemination will be initiated at the outset of the project and
will be continuously carried out during each of the project phases. We will build up a website or
database in our internal network. The website is protected by password, so only the project team
can access the documents concerning technical design, layout, etc.
• External dissemination: The external dissemination is carried out via a project website, which can
be accessed by all target groups and the general public, providing the relevant information on the
project activities such as project brochure, press releases, news about events, meetings, workshops.
b. Communication activities
The main purpose of our activities is to attract a larger target group who might be interested in the
final products.
1. As soon as the project is started, we will purchase a domain for the website, preparing and
setting up the website in English.
2. Media communication and press releases: In order to generate wider interest for the project
activities, we will also use press releases from other media channel such as Danish Industry and so
on.
3. Social media Online: We will publish selected news on the LinkedIn and/or Twitter profiles
of each of the partnering institutions. The project outcomes and results will reach very broad
population in a direct way and will give wide visibility of the project. The number of followers,
network page views, page comments, re-tweets etc. will be a measure of successfulness of this
dissemination channel.
4. Promotional flyers: A brief summary of the project will be available in hardcopy and
electronically.
5. Workshops: The workshops within this project will be aimed for sharing knowledge with
our business partners and society. Additionally, the project results and outcomes should be
presented on national and international conferences and other relevant scientific and business
events.
Reference:
1.Resources | LpR Article | SciPiL | Micro-Optics | Manufacturing | Oct 15, 2018
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Roll-to-Roll UV Nanoimprint Lithography for Large-Area Nano- and Micro-Structuring of Flexible
Substrates
2. Global printing market to top $980 billion by 2018
https://www.smitherspira.com/news/2014/january/global-printing-market-to-top-980-billion-by-
2018
3. Anti-Counterfeit Packaging Market by Technology (RFID, Barcode, Hologram, Taggants),
Usage Feature (Overt & Covert), End-Use Industry (Food & beverage, Healthcare, Electronics &
automotive, Consumer durables), and Region - Global Forecast to 2023
https://www.marketsandmarkets.com/Market-Reports/anti-counterfeit-packaging-advanced-
technologies-and-global-market-129.html
ResearchGate has not been able to resolve any citations for this publication.
ResearchGate has not been able to resolve any references for this publication.