Electromagnetic embossing of optical microstructures

电磁压印是一种很有前途的高速复制功能和光学微结构的方法。对于箔的压花，它提供了不同的优势，例如无接触的工作体积力和省略润滑剂，如轧制油。特别是对于微结构的压印，由于增加的复制精度，增加的塑性是有益的。由于工艺机制和物理效应对材料行为的相互作用的影响仍然是部分未知的，因此目前不可能对光学微结构的电磁压印进行工艺控制。因此，该研究所bime和LFM的联合研究项目将侧重于通过电磁压印复制大面积功能和光学微结构，目的是获得基础工艺力学的具体知识。在这种情况下，相对于工艺参数的材料流进行实验研究，并确定一组参数相关的流动曲线。建立了一个仿真模型，以可视化的物理效应，影响材料流动和相关的流动曲线的主要机制及其相互作用。此外，电磁和机械负载的出现需要定制的压印工具。因此，将开发和研究包括选定的基础材料和涂层的不同制造策略。将通过实验确定不同结构类型和表面的不同负载对压印质量的影响。这包括在高冲击载荷下微观结构的行为。除了可实现的表面质量，工具和浮雕微观结构的轮廓偏差将进行分析。工具设计战略将是这些研究结果的结果。在此基础上，建立了面向应用的系统化工艺布局模型和方法，并通过典型的压印实验进行了验证。

Electromagnetic embossing is a promising high speed process for the mass reproduction of functional and optical microstructures. For embossing of foils it offers different advantages such as a contactless working volume force and the omission of lubricants like rolling oil. Especially for embossing of microstructures the increased plasticity is beneficial due to an increased replication precision. As the influence of process mechanisms and interactions of physical effects on the material behavior is still partially unknown, a process control of the electromagnetic embossing of optical microstructures is currently not possible. This joint research project of the institutes bime and LFM will therefore focus on the replication of large-area functional and optical microstructures via electromagnetic embossing, with the aim of obtaining a substantiated knowledge of the underlying process mechanics. In this context, the material flow with respect to the process parameters is experimentally investigated and a set of parameter dependent flow curves is determined. A simulation model is set up to visualize the physical effects that influence the material flow and to correlate the flow curves to main mechanisms and its interactions. Furthermore, the occurrence of both electro-magnetic and mechanical loads requires a customized embossing tool. Thus, different manufacturing strategies comprising selected base materials and coatings will be developed and investigated. The influence of varying loads on the embossing quality of different structure types and surfaces will be determined experimentally. This includes the behavior of the microstructures under high impact load. Besides the achievable surface quality, the contour deviations of the tools and the embossed microstructures will be analyzed. A strategy for the tool design will be the outcome of these findings. Based on the overall achievements an application-oriented model and a method for a systematical process layout will be set up and verified against exemplary embossing experiments.