Executive Summary : | Roll-to-roll technologies have seen significant growth in recent years, offering low unit costs, high-volume production rates, process efficiency, and low weight in various industries. However, most work is done for micometer-level features, and the roll-to-roll technique is most suitable for developing micro or nano textures over wide surfaces. A micro or nano structured roller is required for the roll-to-roll replication process, and ultra-precision machining is best suited for the roller mold. The proposed work aims to manufacture and replicate functional micro-nano structures on polymers using the roller Imprint technique. The process will be demonstrated by replicating optical structures like micro-lenslet arrays, optical gratings, and diffractive structures. The ultimate goal is to develop the process chain, including the development of textured roller mold, setup development, modeling, and optimization of the replication process, and demonstration of the replication process for Micro or Nanostructures. The developed setup will be capable of replicating Micro or Nanostructures on 100mm wide and 1000mm long polymer sheets, with a target TRL level of 4 to 5. The technology and know-how will be transferred to industries to scale up the production of micro or nano structured surfaces. |