Roll-to-roll (R2R) hot embossing for structuring 3D microstructures on polymer films

Large area polymer films with patterned microstructures are expected to be widely used in various areas, such as functional optical films for flexible displays, lighting devices as well as structured films for microfluidic components. Large area embossing is a promising method for patterning microstructures on polymer substrates. We have investigated the process feasibility of roll-to-roll hot embossing as well as roll-to-plate hot embossing for large area, high-volume fabrication of microstructures on polymer substrates. Micro pillar (with diameter of 50μm) arrays were formed on polypropylene films via both roll-to-roll and roll-to-plate hot embossing. In this paper, we will report our achievement in roll-to-roll process study and explore potential industrial applications.