Roll-to-roll large-format slot die coating of photosensitive resin for UV embossing

Roll-to-roll large-format coating and UV embossing processes aim to revolutionise the manufacturing of functional films, with the ability to process a largearea at one time, resulting in high throughput and cost reduction. In this article, we present the experimental results obtained during the process development for roll-toroll large-format coating and UV embossing. We have investigated key areas of the processes with the aim of improving them in the long term through the understanding of the key factors associated with them and their effects on the processes. The areas investigated are the UV-curable liquid resin, the roll-to-roll film substrate, the coating process and quality, and the UV embossing process and quality. The emphasis is placed on the investigation of the coating process and quality. The results show that the rollto-roll coating and embossing processes are capable of producing micro-scale structures and functional devices over a large area at one time. They are complex processes with many factors playing important roles.