Microstructured precision moulding roller production

Surface relief microstructured optical film can be manufactured using a reel-to-reel process by precisely coating a base film material with a UV curable lacquer. The base film and lacquer are compressed against a suitably precision structured moulding drum and a high intensity UV light cures the material whilst still in contact with the roller mould. The film, with the now structured polymer on it surface, then peels off the drum and is collected, or laminated with a protective film.

In order to produce film with surface structures in the 20 to 400 micron range, precision surface features need to be generated on the surface of the casting roller. This is achieved using precision diamond cutting of specific types of metal surfaces, which enable cutting but are hard enough to achieve a mirror finish and robust enough to generate large quantities of film.