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Study of a Dot-patterning Process on Flexible Materials using Impact Print-Type Hot Embossing Technology
Published on: April 6, 2020
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Circumferential Bulging Variation and Temperature Distribution of Profile-Tunable Roll for Freeform Optics in
Yanfeng Feng1,2, Lixiong Luo1, Yujie Zhou1
1Shenzhen Key Laboratory of High-Performance Nontraditional Manufacturing, College of Mechatronics and Control Engineering, Shenzhen University, Shenzhen 518060, China.
Micromachines
|December 31, 2025
Summary
A novel profile-tunable roll was developed to overcome limitations in freeform optics fabrication using roll-to-plate hot-embossing. This innovation enables precise control over optical element shapes for high-volume, low-cost production.
Area of Science:
- Optical Engineering
- Materials Science
- Manufacturing Processes
Background:
- The roll-to-plate (R2P) hot-embossing process is effective for large-area microstructured optical elements.
- Current R2P technology is limited to flat surfaces due to the cylindrical nature of the roll and varying optical plate thickness.
Purpose of the Study:
- To develop a new profile-tunable roll capable of fabricating freeform optical plates.
- To investigate the relationship between roll temperature, profile deformation, and fabrication parameters.
Main Methods:
- Development of a profile-tunable roll incorporating semiconductor heater/coolers (SHCs).
- Circumferential finite element modeling using MSC.MARC 2020.
- Experimental verification of the model on a dedicated platform.
Main Results:
- Demonstrated tunable roll profiles by regulating SHC current and roll temperature.
- Established fundamental relationships between bulging values, temperature distribution, and roll/SHC parameters.
- Verified the finite element model against experimental data.
Conclusions:
- The profile-tunable roll provides a unique, low-cost fabrication method for high-volume optical freeform plates.
- This research lays the groundwork for future studies on axial deformation and temperature distribution in freeform optics manufacturing.
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