Optimization of a continuous hot embossing process for fabrication of micropyramid structures in thermoplastic sheets

Reported is the manufacture and optimization of inverted micropyramid cavity structures into thermoplastic sheets using roll-to-roll (R2R) embossing. To master, an ultraprecision diamond machining method was applied to create seamless surface a copper-coated hot embossing roller. Using process, roller features were successfully transferred 2 mm thick polymethyl methacrylate (PMMA) sheets. Optimization R2R control process variables conducted Taguchi's numerical methods, which showed importance temperature for successful pattern transfer. The work presents novel fabrication technique that allows microstructures be manufactured PMMA in continuous process.