Professionals working with micro and nano-scale structures must consider precision, efficiency, and cost when selecting a replication method. Injection moulding has long been the industry standard for mass-producing plastic components, but when it comes to intricate nano-features, Rolling Nanoimprint Lithography (RNIL) emerges as a superior alternative.

Stensborg, with 25 years of experience in nanoimprint lithography and holographic masks, provides customisable high-performance RNIL systems that surpass the limitations of traditional injection moulding. In this technical article, we explore the key differences between these technologies and why roller-based nanoimprinting is the smarter investment for high-precision applications.

Image credit: Stensborg A/S and iStock

Understanding the wide use of injection moulding

Injection moulding is a well-established method for mass-producing larger products, from commonly used plastic chairs to consumer electronics components. It involves injecting molten thermoplastic into a pre-designed mould, cooling, and ejecting the solidified structure, making it highly effective for large-scale productions where the final design is already fine-tuned.

However, for manufacturers requiring ultra-fine micro and nano features, injection moulding presents several challenges. Micro injection moulding struggles with sub-micron features due to polymer flow constraints and heat expansion, typically achieving structures in the 10 to 100-micrometre range. It is primarily limited to thermoplastics, with UV-curable alternatives still in early development. Additionally, mould wear, bubble entrapment, and thermal expansion often lead to inconsistencies in replication. The high initial investment and costly tooling also make small to medium-scale production less viable.

As industries push the boundaries of microstructure replication, alternative technologies like UV curing Rolling Nanoimprint Lithography (RNIL) offer a more precise and scalable solution.

Rolling Nanoimprint Lithography: A new era of precision manufacturing

Rolling Nanoimprint Lithography (RNIL) revolutionises nanostructure development by enabling continuous, high-precision replication on various materials. Unlike traditional Nanoimprint Lithography (NIL), which uses a flat process, RNIL employs a rolling motion process in 2 configurations, Roll-to-Roll (R2R) for flexible materials and Roll-to-Plate (R2P) for rigid materials, allowing seamless, high-throughput productions with high-precision nanoimprinting on a variety of substrates.

Our advanced RNIL technology also utilises a patented optical engine, included in all our equipment and specially designed for fast and highly accurate UV curing. With better uniformity, higher speed and continuous production abilities, roller-based Nanoimprint Lithography (RNIL) has evolved from a research-focused technology to one increasingly adopted in high-volume industrial production for small and large patterns.

How Stensborg’s rolling nanoimprinting systems outperforms injection moulding for nanostructure productions

1. Superior micro-feature resolution & replication precision

Achieving feature sizes down to a few nanometers and up to 100 µm (micrometers) makes it an ideal solution for applications in micro-optics, microfluidics, and other high-precision fields.

2. Continuous high-throughput production

The use of a stamp carrying roll allows for faster and continuous production without deteriorating the master structures, reducing cycle times while ensuring more reliable uniformity and output quality. A more cost-effective nano manufacturing solution when compared to batch-based processes like injection moulding.

3. Efficient processing & energy advantage

Injection moulding demands prolonged heating and cooling cycles, often resulting in slower throughput and higher energy consumption, especially for micro-structured parts where dimensional stability is critical. In contrast, UV-based nanoimprint lithography (UV-NIL) uses resins that cure instantly under UV light, enabling faster cycle times and significantly lower thermal load. This not only reduces energy usage but also minimises thermal expansion effects, improving feature fidelity and reproducibility, making UV NIL a more efficient alternative to traditional high-temperature moulding techniques.

4. Material & design versatility

Unlike injection moulding, which is constrained by temperature requirements, rolling UV-NIL is compatible with optical-grade polymers, functional coatings, and both flexible and rigid substrates, giving researchers greater design freedom. Learn more about our in-house portfolio of consumables and UV resins.

Is RNIL the right investment for your application?

As industries race toward miniaturisation, performance enhancement, and mass customisation, roller-based Nanoimprint Lithography (RNIL) is emerging as a strategic manufacturing enabler. Combining nanoscale precision, scalability, and cost-effective throughput, RNIL is already unlocking next-gen product innovation across high-impact sectors:

  • Photonics & AR/VR Optics: RNIL enables high-speed replication of complex optical architectures such as diffractive gratings, microlens arrays, holographic patterns, and meta-optical surfaces. It’s paving the way for wafer-level optics used in augmented reality (AR), light-field imaging, and next-gen sensing platforms.

  • Advanced Electronics, Semiconductors & Battery Tech: With its ability to create surface-engineered nano-topographies and high-fidelity pattern transfer masks, RNIL supports cutting-edge processes in advanced packaging, 2.5D/3D integration, solid-state batteries, and functional substrate engineering, driving the next wave of Moore’s Law and beyond.

  • Renewable Energy & Photovoltaics: From nanostructured anti-reflective coatings to Fresnel lens arrays and light-trapping textures, RNIL enhances the efficiency of next-gen solar modules and optical concentrators, supporting net-zero transitions and energy-positive materials.

  • MedTech, Diagnostics & Microfluidics: RNIL enables cost-effective mass production of lab-on-a-chip platforms, bioanalytical surfaces, and microscale diagnostic devices for healthcare applications, contributing to improved personalised medicine, point-of-care diagnostics, and organ-on-chip systems.

Stensborg supports both cutting-edge research and industrial-scale production. Our compact, turnkey Desktop R2P Nanoimprinting system is ideal for R&D and prototyping, while our custom-built large-format RNIL machines are designed for continuous, high-volume nanostructure replication for advanced manufacturing environments.

Small-batch injection moulding is often cost-prohibitive and impractical for university labs and research institutions working on cutting-edge innovations. That’s why Stensborg offers a compact Desktop Roll-to-Plate solution that is both affordable and efficient for testing parameters and optimising workflow.

Future-proof your production with Stensborg: Join a growing community of innovators

While traditional injection moulding remains effective for macro-scale plastics, roller-based Nanoimprint Lithography (RNIL) is the go-to solution for applications demanding nano-level precision, fine-feature replication, design agility, and high production consistency.

Stensborg has successfully delivered tailored NIL solutions to over 25 research facilities worldwide, supporting a wide range of industries and applications. Whether you’re new to nanoimprinting or scaling up complex, high-precision production, our experts are here to match you with the right tools to push boundaries and stay ahead of the curve.

Explore our portfolio of rolling nanoimprint lithography systems to find the ideal fit for your development stage and application goals