Direct fabrication of microstructures on metal roller using stepped rotating lithography and electroless nickel plating
Date Issued
2009
Date
2009
Author(s)
Huang, Tzu-Chien
Abstract
Roller embossing has attracted more attention due to its rapid, continuous nature; it is especially good for mass production. The fabrication of microstructure rollers is the key technology. Most of the microstructure rollers fabrication methods are very complicated and costly, employing high-end facilities. Furthermore, mold sliding and warping problems are frequently encountered because of the weak adhesion between molds and rollers. Soft rollers with microstructures have problems such as poor strength durability and temperature endurance.his work proposes a novel fabrication method of roller mold with microstructure on the surface using stepped rotating lithography and electroless nickel plating. First of all, the photoresist is coated onto the roller surface using three methods: dip coating, rotatory dip coating and electrostatic coating. Then the photoresist on the roller surface is patterned using stepped rotating lithography, followed by developing. The roller is subsequently treated with electroless nickel plating. Finally, the residual photoresist is removed. A roller with rigid nickel microstructures can be obtained. t was found that the thickness of PR coating on roller are 400-1050 nm using rotatory dip coating, 70-600 nm using dip coating, and 24-100 nm using electrostatic coating. Results prove that the microstructures can be successfully fabricated onto the metal roller using proposed stepped rotating lithography and electroless nickel plating. In addition, the microstructures with various pitches on single metal roller also can be fabricated by adjusting the rotating degree of stepped rotating lithography.
Subjects
Roller Imprint
Microstructures
PR Coating
electroless nickel plating
Type
thesis
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