Scalable production of nano- and microstructures

Whether in machining, additive manufacturing, or laser ablation processes, the production of micro- and nanostructures requires the highest degree of accuracy and precision.

Optical structures down to just below one micrometer can be produced in machining with monocrystalline diamond as the cutting material. Accessibility for the tool tip is usually the only limiting property here. In 2-photon lithography, an additive process for structures in the nanometer range, only the writing speed sets economic limits. Laser structuring can be used to provide particularly large areas with deeper structures at comparatively low cost. In all these processing methods, however, the requirements for accuracy and precision extend not only to the manufacturing technology used, but also to the upstream and downstream processes.

At Fraunhofer IPT, we bundle competencies across a wide range of production technologies so that all manufacturing stages can be reliably and fully tested. This enables us to develop complete process chains for the manufacture of a wide variety of products with different requirement profiles and bring them to industrial maturity. Examples from this product spectrum include retroreflectors, microlens arrays or aesthetic natural patterns for molded plastic surfaces.

Laser ablation, planing, grinding, fly-cutting, embossing or lithography: Microstructured components can be manufactured using various processes. With our comprehensive process know-how, we put together the best process chain for each individual application in order to manufacture high-quality components economically.

It is only through replication techniques that it is possible to manufacture many products at a marketable price. That is why numerous process chains today rely on these methods for replication.

Fraunhofer IPT not only continues to develop the discontinuous processes of glass forming and injection molding as well as continuous roll-to-roll processes, but is also involved in electroforming for the true-to-shape replication of structures down to the nanometer range. Added to this are multi-step embossing processes to combine small structures on large surfaces.

Our range of services here includes the development of tools and processes for mass production, for example for Fresnel optics, for micro-lens arrays (MLA) made of glass and plastic or for flexible diffuser or antimicrobial protective films, as well as the manufacture of tools for mastering processes, which often enable the cost-reducing upscaling of production in the first place.