FLEXPAET

Flexible Patterning of Complex Micro Structures using Adaptive Embossing Technology

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 Obiettivo del progetto (Objective)

'Compared to conventional light sources, the light producing capacity of a light emitting diode (LED) is virtually unlimited at about a 1/10 of the energy consumption rate and a fraction of the production cost. Due to its point source characteristics an LED requires a means to collimate and shed the emitted light onto larger areas. Diffractive optics (DO) elements consisting of highly complex micro structured surfaces provide a solution to this problem, allowing the controlled collimation and distribution of point source light. However, there are significant challenges associated with the production of DO-elements making them expensive and limit size as well as achievable illumination performance. In order to exhaust the vast potential of LED illumination, an economic solution of the production of high performance DO-elements is required. Therefore, in the proposed project a new technology will be developed, providing a high throughput, highly flexible process for the patterning of large area complex micro structures, thus allowing the low cost, high volume production of large area micro structured surfaces for the use in diffractive optics elements. The proposed work will result in a novel technology for high volume production of DO-patterned surfaces, answering to an ever increasing demand for advanced light management and illumination solutions. More importantly even, this technology will bridge the gap between conventional micro manufacturing technologies and industrial scale, cost effective production of a new generation of innovative, high value added products. The proposed project will contribute directly to the creation of new capabilities at the European level, enabling the transfer of laboratory scale manufacturing processes to an industrial scale production of high quality, large area DO-elements for use in a variety of advance lighting solutions, thus strengthening Europe against Asian competition in the lucrative high end consumer products market.'

Introduzione (Teaser)

A faster manufacturing process with more efficient components that reflect and refract light will propel the eco-friendly LED lighting technology into full bloom.

Descrizione progetto (Article)

Light emitting diodes (LEDs) are all the rage in the lighting industry - they are much more energy efficient and cost effective compared to traditional lighting. LEDs are now used not only to illuminate rooms, but also in TVs, monitors and a wide variety of electronics and appliances.

While LED technology is catching on everywhere, there are still some challenges to overcome, such as dispersing the light effectively over large areas. This requires advances in the area of diffractive optics (DO), i.e. the development of highly complex micro-structured surfaces that distribute light evenly and efficiently. DO technology reflects, combines and refracts light to harness its intensity.

However, DO elements are expensive to produce and can limit lighting performance. The EU-funded 'Flexible patterning of complex micro-structures using adaptive embossing technology' (Flexpaet) project is working on improving the production of micro-structure surfaces used in DO elements and on decreasing their cost.

The project is working to bridge the gap between conventional micro-manufacturing technologies, generating industrial-scale, cost-effective production of a new generation of innovative, high value-added products. To achieve this, Flexpaet is working to enable the transfer of lab-scale manufacturing processes to an industrial-scale production of high-quality, large-area DO elements for a variety of advanced lighting solutions.

Flexpaet has yielded strong results that are likely to advance the LED lighting sector. To illustrate, micro-embossing is an important part of DO technology, requiring complex studies and tests. Not only has the concept for micro-embossing been validated but also the entire process chain. The process begins with micro-machining of tools for new optical designs, ending with the mass production of micro-structured samples. So far, micro-embossing and replication of the desired components have been realised for relatively small surfaces. The second half of the project is focusing on processing surfaces up to 2 metres squared, opening up the industry to a variety of applications.

Combined with this new process for making DO components, LED lighting is set to take off exponentially, and Europe will be at the core of this innovative technology. Indeed this work stands to strengthen European industry against Asian competition in the lucrative high-end consumer products market.