The Roll-to-Roll (R2R) Platform
Our unique large-scale replication technique utilizes thermoplastic polymers, allowing us to produce customized thermoplastic films with a thickness up to 300 μm. Whether you are looking for a highly-tailored solution for your specific needs or are simply looking to explore the incredible potential of thermoplastic film technology, we have you covered.
Our Patented Technology
Our patented high throughput R2R replication line allows fast replication of customized patterns in thermoplastic polymers. The fabricated patterns will be analysed using inline quality control.
The technology provides a scalable and cost-efficient route to manufacturing imprinted films in high volumes. These films can be combined with existing injection-moulded components, enabling lighter and more compact products while reducing material usage and overall CO₂ emissions.
Advantages
High-throughput
- Standard film width 450mm (with upscaling potential up to 1.5m)
- High replication speeds
- Potential production volume of several million m2/year
Thermoplastics
- Replace injection molded parts easily with films imprinted in the same material
- Compatible with injection molded counterparts
- Established surface funtionalization and bonding methods applicable
Thin film
- Reduce CO2 footprint through material saving
- Reduce product dimensions (volume)
- Allow replication of large area imprint
We provide four Roll-to-Roll processes
Extrusion Casting
Manufacturing of thermoplastic films with tailored thickness, composition, and properties.
Molten polymer is pushed through a flat die onto a chilled roller and cooled to form a smooth, thin and continuous film. Material selection, thickness, layer structure, and functional additives can be customized to meet specific application requirements. The process is ideal for producing monolayer and multilayer films.
Extrusion Coating
Application of one or more thermoplastic layers onto an existing substrate.
Molten polymers are directly coated onto substrates, which can be polymer films, paper, textiles, foils, or membranes. The substrate remains an integral part of the final product. Multiple layers of polymers can be combined in a single process (Coextrusion Coating) to provide adhesion, sealing, barrier properties, protection, or surface functionality.
Extrusion Lamination
Extrusion lamination is used to create multi-layer structures by combining two different substrate materials into a single construction. This allows the finished material to incorporate the unique and desirable properties of each individual layer.
Similar to extrusion coating, a molten polymer is extruded through a flat die. Instead of being applied to a single substrate, however, the molten polymer is introduced directly into the nip point between two moving substrate webs. The hot polymer acts as an adhesive, while pressure rollers immediately bond the three layers together to form a unified laminated structure.
Structured Film Fabrication
Creation of micro- and nano-structured film surfaces for advanced functionality
Using roll-to-roll replication technology, surface textures are integrated directly into the film during production.
The technology can be combined with both extrusion casting and coextrusion coating to produce either structured freestanding films or structured coated materials. Typical functionalities include optical effects, wettability control, microfluidic features, adhesion management, and bio-inspired surface engineering.
Curious if your project is suitable for the replication?
Consider our Service Packages which cover preparation, execution, and analysis of the test replication with a custom design.
