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Fabrication of complex periodic patterns on a metallic drum for high throughput roll-to-roll processing

: Voisiat, Bogdan; Menzel, Max; Wang, Wei; Fu, Yangxi; Soldera, Marcos; Lasagni, Andrés-Fabián

Wissenschaftliche Gesellschaft Lasertechnik -WLT-:
Lasers in Manufacturing Conference 2021. Proceedings : June 21 - 24, 2021, held virtually, part of the World of Photonics Congress
Erlangen: WLT, 2021
9 S.
Lasers in Manufacturing Conference (LiM) <2021, Online>
World of Photonics Congress <2021, Online>
Bundesministerium fur Wirtschaft und Energie BMWi (Deutschland)
Fraunhofer IWS ()
direct laser interference patterning; diffraction gratings; structural coloration; roll to roll

In this study, the development of complex periodic structures on massive metal drums by means of direct laser interference patterning (DLIP) is demonstrated. The DLIP technology allows the formation of high-resolution periodical structures (even with sub-micrometer resolution) at high fabrication speeds on large surface areas. These advantages drastically reduce the patterning costs of the drums that are broadly used in roll-to-roll processing. We demonstrate the ability to control individually each laser spot (e.g. period) to form complex periodical patterns to be used as decorative elements exhibiting structural colors. These patterns are then replicated on a polymer foil by an industrial hot-embossing roll-to-roll process at speeds up to 50 m/min. This process brings the industrial fabrication of such patterns to the next level in terms of throughput and is thus suitable for mass production.