ROLLING NANOIMPRINT LITHOGRAPHY TECHNOLOGY
ROLLING NANOIMPRINT LITHOGRAPHY TECHNOLOGY
High-Throughput UV-Based Nanoimprint Lithography Using Patented Roller Systems
Stensborg’s core technology is Rolling Nanoimprint Lithography (RNIL): a scalable, high-resolution nano-fabrication method designed for both R&D and high-volume industrial production. Unlike Plate-to-Plate/Flat-to-Flat imprinting, our patented roller-based systems combine precision with productivity and efficiency, supporting both Roll-to-Roll (R2R) and Roll-to-Plate (R2P) nanoimprinting on diverse substrates.
Our IP-backed Optical Engine, embedded in every system, delivers focused UV-curing directly at the nip point where resin and template meet. This enables accurate pattern replication down to 20 nm at various speeds. Engineered for small feature replication, Stensborg’s RNIL solutions are used globally across industries such as: micro-optics, diffractive optics, AR/VR waveguides, flexible electronics, semiconductor nanostructures, microfluidic devices, photovoltaic, and battery technologies.
INDUSTRIAL/ HIGH-VOLUME PRODUCTION
Roll-to-Roll
A continuous nanofabrication method engineered to replicate micro and nano-scale features onto flexible substrates at industrial throughput. The system’s modular, versatile design can be customised to suit specific production requirements, driving maximum efficiency and cost-effective scaling for optimal, commercially viable results.
COST-EFFECTIVE PROTOTYPING & PROCESS VALIDATION
Roll-to-Plate
A scalable, high-throughput imprinting method engineered for replicating nano patterns onto rigid substrates. Whether implemented in a full-scale industrial system or as a compact tabletop unit, R2P offers a highly accurate, cost-efficient nanoimprint lithography (NIL) solution, making it ideal for advanced prototyping and medium-volume commercial rollout.
IP-Backed Technology: Stensborg’s Optical Engine
Exclusive to Stensborg, our patented Optical Engine houses a UV-curing light source within the cylinders to optimise nanoimprint resolution and efficiency. During operation, the NIL template—mounted on the roller—contacts a UV-curable resin on the substrate. The focused UV light activates instant curing precisely at the nip point, enabling the accurate replication of nanoscale features through a clean, three-step process: Contact, Cure, and Release.
This method minimises air entrapment, reduces demoulding defects, and maximises yield while reducing resin waste. It simultaneously enables real-time curing at industrial throughput.
Compared with traditional nano replication techniques, Stensborg’s solution delivers superior pattern fidelity alongside a faster turnaround from concept to production, all while significantly lowering energy consumption.
IP-Backed Technology: Stensborg’s Optical Engine
Exclusive to Stensborg, our patented Optical Engine houses a UV-curing light source within the cylinders to optimise nanoimprint resolution and efficiency. During operation, the NIL template—mounted on the roller—contacts a UV-curable resin on the substrate. The focused UV light activates instant curing precisely at the nip point, enabling the accurate replication of nanoscale features through a clean, three-step process: Contact, Cure, and Release.
This method minimises air entrapment, reduces demoulding defects, and maximises yield while reducing resin waste. It simultaneously enables real-time curing at industrial throughput.
Compared with traditional nano replication techniques, Stensborg’s solution delivers superior pattern fidelity alongside a faster turnaround from concept to production, all while significantly lowering energy consumption
OUR FLEXIBLE RNIL SOLUTIONS
Rolling Applications in the Real World
FAQs
TECHNICAL INFORMATION AND RESOURCES
Stensborg’s Rolling Nanoimprint Lithography systems currently support imprinting areas up to 450 x 628 mm, ensuring high-volume capability for your most demanding industrial applications.
Our systems offer customisable imprinting speeds, from as low as 0.005 m/min up to a high-throughput of 50 m/min, providing maximum flexibility for applications spanning basic R&D through to full industrial nano-fabrication.
Stensborg’s RNIL systems can replicate a variety of features, some examples being:
- Nanostructures
- Linear Gratings: Period >100 nm, height ∼ 100 nm
- Holes on Square Lattice: Period >100 nm, height ∼ 100 nm
- Microstructures
- Sawtooth features: Period >90 μm ,height > 35 μm
- Microfluidic Channels: Depth ∼ 40 μm, width ∼ 100 μm
We’ve also demonstrated nano-regime replication of features down to 350 nm (such as nanoholes – see here) and microstructures up to 100 µm in height. To define the optimal parameters for your specific design, contact our specialists today to schedule a tailored proof of concept trial.
Yes. Stensborg’s RNIL systems are specifically engineered to achieve high-fidelity replication of challenging high-aspect-ratio micro- and nanostructures. To review our demonstrated capabilities, please visit our Roll-to-Roll and Roll-to-Plate technical pages.
The optical engine is powered by high-reliability LED technology, operating at a precise 395 nm wavelength. This robust design ensures an exceptional operational lifespan, expected to exceed 40,000 hours, significantly contributing to system uptime and low maintenance. Learn more about our core IP technology here.
NIL consumables, including UV resins, templates, and template-making materials, can be produced in-house or supplied by Stensborg, which has extensive experience across a wide range of structural typologies.
Yes. Our Rolling Nanoimprint Lithography (RNIL) method is compatible with a wide range of substrates, including uncoated materials, foils, metals, and glass. Achieving optimal results on uncoated materials may require process adjustments. We recommend that you contact Stensborg’s specialists to confirm full substrate compatibility for your specific application.
While specific scientific papers focusing solely on Stensborg’s compact Desktop unit are not yet available, the underlying Roll-to-Plate replication method is fully documented. We invite you to explore the extensive applicability and technical results of our method for microfluidic devices here.
Our Rolling Nanoimprint Lithography desktop systems include an integrated water cooling option. While a standard external water cooler can be attached optionally, our patented Optical Engine features a built-in two-step alarm and auto shutoff system to ensure operational safety and reliability.
For continuous operation at maximum line power, we recommend utilizing the external cooler or incorporating brief interval pauses if running at low speeds.
Yes. Replication on reflective materials is fully supported because our patented Optical Engine is specifically designed and optimised to manage reflective light. Working in collaboration with your team, we adjust the necessary process parameters to achieve maximum pattern fidelity on your substrate.
Reproducibility is robust but inherently depends on the entire system, specifically the imprint template material grade (which dictates longevity), operational environment (e.g., dust and adhesion), and the actual feature design being replicated (e.g., aspect ratio and size of micro- or nano-features). While quick-fabrication templates have a shorter lifecycle, we routinely see high-quality templates surpass thousands of imprints while maintaining dimensional stability. We recommend a process consultation to define the optimal template and environment for your target volume and feature requirements.
Yes. Stensborg offers comprehensive, end-to-end support, spanning initial design consultation and high-fidelity mastering services. We leverage both our specialised in-house nanofabrication capabilities and our robust network of trusted local and global subcontractors to deliver all required masters and templates for the NIL process.
Our dedicated demo video provides a clear, visual guide, illustrating the straightforward tape method for properly aligning your template and creating your replica on the Desktop Roll NanoImprinter 3.0 cylinder. Furthermore, to accelerate client success, we provide comprehensive start-to-finish instructional videos and workshop sessions immediately following purchase, ensuring all development needs and questions are quickly addressed.
Template stability is achieved by mounting the imprinting template under mechanical tension and securing it with edge tape, the primary means of preventing slip during operation. Stensborg’s RNIL process itself promotes stability, as diffused mechanical forces impose minimal strain on the template. For enhanced security, supplementary fixation with double-sided adhesive may be applied, though adhesion at the leading edge is generally sufficient, and full-surface backing is seldom required.
Yes. When imprinting on thick and narrow substrates, such as glass slides, it is essential to use at least an improvised compound bearer stripe. Without it, you risk leaving marks on the cylinder and damaging your imprint.
A practical approach is to mount a larger base plate (similar in size to the provided 155 mm × 315 mm glass plate) with double-sided adhesive. Rows of your substrates can then be fixed onto the adhesive, forming a functional bearer stripe. This arrangement distributes load evenly, prevents jumps in thickness, and increases imprint stability.
In the illustrations (below), the green area represents the adhesive, black the supporting material, and red the imprint sample. Overlaps between substrates further stabilize the process, reducing the risk of sudden height transitions that could cause cylinder damage.
Benefits of proper bearer stripes:
- Enable accurate adjustment of cylinder alignment to the plate thickness.
- Ensure continuous contact between the driven plate and the cylinder at all times, preventing crashes.
- Stabilise the imprinting process by avoiding abrupt changes in load, improving imprint quality and tool lifetime.
Substrates are typically held in place using tape or, in some cases, solely by friction, depending on substrate properties. For added stability, substrates may also be secured using additional plate/substrate holders mounted onto the base plate, or by employing designated three-point register nodes. Where higher precision or repeatability is required, custom solutions such as dedicated substrate holders or small vacuum tables can be implemented.
Resin is applied externally, prior to imprinting, using conventional deposition methods such as hands-down, spin-coating, slot-coating, or inkjet printing.
If the imprint template is mounted on a sacrificial foil (supplied with the compact Desktop nanoimprinting unit), the simplest and safest method is to remove the foil from the cylinder. To further minimise residue, we recommend using only low-tack tape to secure the edges.
The chemistry supplied with the system allows imprinting templates to be tailored to customer requirements. In general, it should be formed from a flexible material that is operable to conform to the curvature of the cylinder. It can be formed from any suitable material transparent for 395nm, for example: Polydimethylsiloxane (PDMS), Cyclic Olefin Copolymer (COC), or other light-curing resins/polymers.
Resin buildup on the soft backing layer should be prevented by using a sacrificial foil beneath the imprint plate. This protects the soft layer, as misprints can be resolved by replacing the foil rather than cleaning. When mounting manually, apply tension in the running direction. If mounting directly on the soft layer, extend the plate ≥200 mm beyond the active area to keep tape outside the imprint zone and reduce resin contact.
