Polygon scanner based ultra-short pulse laser processing in roll-to-roll manufacturing

Transcription

1 Polygon scanner based ultra-short pulse laser processing in roll-to-roll manufacturing Development of high speed ultra-short pulse laser ablation process integrated into a roll-to-roll machine Name Surname, Company This project has received funding from the European Union s Horizon 2020 research and innovation programme under grant agreement

2 Contents The Challenge PoLaRoll Project PoLaRoll Consortium PoLaRoll Objectives PoLaRoll Concept Methodology Impact Contact Slide 2

3 The Challenge Roll-to-roll manufacturing is well established in many segments like electronics, micro manufacturing or solar technology Continuous roll-to-roll manufacturing processes can be integrated with various manufacturing steps within the production line While many conventional and laser manufacturing techniques could already be embedded successfully into roll-to-roll machines, pulsed laser structuring could not be adapted sufficiently The main obstacles are insufficient pulse repetition rate levels with required pulse energy and beam deflection speed and accuracy Slide 3

4 PoLaRoll Project BUDGET 4.4 Million COORDINATOR Fraunhofer IPT DURATION Start date duration 36 months WPs 10 Workpackages PARTNERS 7 partners Slide 4

5 PoLaRoll Consortium Slide 5

6 PoLaRoll Objectives The overall objective of PoLaRoll project is to substitute the lithography step in current etching processes by directly structuring the lacquer with the PoLaRoll laser micro machining unit Slide 6

7 PoLaRoll Objectives Obj 1: Development of a high performance laser source Huge improvement on the system s pulse repetition rate and pulse energy An industrial ultra-short pulsed laser source with never before presented specifications on industrial scale for high speed processing Obj 2: Development of a high speed polygon scanner To cope with the new high processing speeds and the high pulse repetition rates achieved To ensure a high accuracy over the high speed laser spot positioning based on the polygon scanning unit for the micro structuring process Slide 7

8 PoLaRoll Objectives Obj 3: Development of two in-line measurement systems for polygon scanner processing Direct measurement of the lacquer ablation results Measurement of the resulting micro structures and inline evaluation of its form and position Based on both units, a control and adaptation of the process will be implemented. This allows an automatic adjustment of laser and roll-to-roll process parameters and quality assurance Obj 4: Laser based micro machining system with synchronisation between laser source and multiple polygon scanners Implementation of a highly innovative ultra-fast synchronisation unit for at least two polygon scanners operated with one laser source Fully usage of all system specifications on real industrial context. Slide 8

9 PoLaRoll Objectives Obj 5: Integration of laser based micro machining system for two sided laser structuring into a roll-to-roll process integration of the final laser micro structuring system including the enhanced ultra-short pulsed laser source and polygon based scanning unit as well as the in-line measurement systems in the roll-to-roll system process synchronization as well as data exchange and product information will be in focus, to warrant high adaptability, modular and robust system integration on industrial standard Slide 9

10 PoLaRoll Objectives Demonstrator To prove the PoLaRoll process performance a target application has been selected: MICRO STRUCTURES FOR SOLAR SHADING OF GLASS FACADES Structured stainless steel with sieve geometry for solar shading applications (source: MicroShade) The geometry allows cutting the solar radiation and therefore reduces the energy used for cooling and ventilation Slide 10

11 PoLaRoll Concept Rapid individualised laser-based production A novel ultra-short pulsed laser source will be developed. Intelligent networking and machine cooperation, data handling and modelling Integration of different processes PoLaRoll will enable the substitution of the masking process with a digital and thus very flexible one Slide 12

12 PoLaRoll Concept Monitoring and process control PoLaRoll will integrate an in-line measurement system in the machine's laser beam optical path Work piece handling and beam delivery PoLaRoll will develop a novel high speed polygon scanner system for high speed beam deflection. Industry driven and include the key stakeholders running the pilot facility Strong industrial commitment on the implementation of single components and of the complete system, is achieved through the participation of industrial partners covering all supply chain units. All process requirements come from a real end-user need Slide 13

13 Methodology Development of high performance laser source Test laser source Development of high speed polygon scanner Test polygon scanner New lacquer development In-line measurement for polygon scanner processing Development of dual polygon scanner system and fast synchronisation with laser source Modular roll-to-roll integration Final in-line measurement system Final dual polygon scanner system Final roll-to-roll module Test of 1 st modular system prototype Final roll-to-roll laser structuring module tests Slide 14

14 Impact PoLaRoll results will help Europe stay competitive on the international market of laser micro machining and roll-to- roll machinery solutions resulting in the following impact: Improved competiveness of laser-based manufacturing industry (equipment and suppliers) and the end-user industry Improved competiveness and strengthened Europe s market position of laser-based manufacturing industry More efficient, more flexible and higher throughput of individualised laser-based production Slide 15

15 Impact Further impacts can be associated to PoLaRoll project: Environmental impacts reduction of unfriendly chemicals demand greener manufacturing reduction of waste management (which represents a direct economical aspect as well) Slide 16

16 Contact Mr. Martin Priwisch Project coordinator - Fraunhofer IPT martin.priwisch@ipt.fraunhofer.de Phone Fax Steinbachstr Aachen Germany PoLaRoll - Polygon scanner based ultra-short pulse laser processing in roll-to-roll manufacturing Slide 17