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Roll-to-Plate Method

Roll-to-Plate nanoimprint lithography is an imprinting process that consists of a roller mechanism and a rigid surface plate.

The core of our roll-to-plate fabrication unit is a transparent cylinder that houses an Optical Engine in the centre - method shown below. 

 

Our NIL imprint template is mounted onto the cylinder to nano pattering the light-curing resin that feeds into the machine. Shortly after the NIL imprint template is in full contact with the resin, the resin will enter the curing stage in the nib. Our approach to Roll-to-Plate is a three-stage process; Contact, Cure and Demould; which all occurs in the nip.

The Roll-to-Plate process and light-based curing method are both used in the Stensborg HoloPrint® uniA6 DT; a patented (patent is applied for) Optical Engine light-curing source located inside the nanoimprint roller.


With the help of ​the University of Copenhagen, this approach has demonstrated the production of microfluidic chips with thiol-ene resins. Read more about this project here.

  • The possibility of using both rigid and flexible base substrates.

  • A small imprinting area, therefore, less imprinting force is required.

  • An ideal method for experimenting and testing new nanoimprinting topologies before mass production, e.g. testing new materials, options for resin, processing parameters, pressure, speed, and light intensity.

The benefits listed above are exclusive to Stensborg’s Roll-to-Plate NIL offering.

Our bespoke solution to Roll-to-Plate NIL requires less imprinting force in comparison to wafer moulding/Plate-to-Plate (P2P NIL) due to the smaller nip contact area (specific to Stensborgs bespoke solution). A nip imprint approach reduces issues concerning trapped air bubbles and can have a built-in compensation for variation of material thickness, which improves replication uniformity.

You can read more about the advantages of the R2P NIL process by downloading the infographic below.

 

The advantages of Stensborg’s Roll-to-Plate NIL:

How can you benefit from introducing HoloPrint®?

 

Security

HoloPrint® technology is a secure in-house manufacturing process for anti-counterfeiting Optical Verification Devices. For added security, we guarantee that all value building takes place in-house.

Flexibility

Imprinting can occur on many base materials. Our process is proven to work on both transparent and opaque substrates, e.g. metal foils, pre-printed paper, and various polymer base materials.

Shorter lead-times

Building small batches of a new design concept can be arranged quickly. Stensborg can rapidly implement trial and demo runs following the establishment and production of a nanoimprint template and agreement on a resin application. 

Reducing cost and CO2 emissions

When compared with traditional nanoimprint volume productions, our HoloPrint® process has less environmental impact due to less energy and material consumption. At Stensborg, our R2R NIL process leaves no waste and works with a highly focused and optimised "cold" light curing source, allowing the user to produce multiple nanoimprints.

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