Microreplication technology is used to produce high aspect ratio precision microstructured geometries in a variety of polymer films. Producing high aspect ratio precision microstructures is a complex multi-step process that involves masking, tooling, mastering and microembossing. There are usually several iterations in the microstructure design and compromises need to be made between desired geometry of the structure and ability of the pattern to be accurately replicated.

 

 

 

 

We typically work with polycarbonate (PC) and polyetherimide (PEI) as thin as 50micron. We have hands-on materials and microembossing expertise to develop a specific microreplication process for a polymer of your choice. We regularly make microreplications of greater than 5:1 aspect ratios and ~250k features per square inch. We can achieve high aspect ratio microreplications of greater than 10:1 on smaller scale samples.

 

 

 

 

 

Cospheric offers microstructure pattern design and materials development, process development, and small-scale microembossing for product design and testing. When your product is ready for manufacturing, we will work with our partners to scale up replication of your pattern up to 1.5m x 2m. We can also apply precision thin coatings on microstructures, and have extensive experience with optically-clear laminations, encapsulations and adhesives (see Coated Microstructures section).