Continuous manufacturing of 3D patterned hybrid film via a roll-to-roll process with UV curing

A strategy for continuous fabrication of a microscale 3D-patterned hybrid composite film composed of alumina and acrylate resin was developed using roll-to-roll production. Conventional thermal curing was replaced with a UV curing procedure to facilitate rapid and economical processing. A seamless engraved soft urethane mold was first produced using a patterned metal roll. Subsequently, alumina and acrylate resin were cured on the engraved mold via UV irradiation to produce patterned hybrid films. The dispersion of alumina particles in acylate resin was enhanced by utilizing amine acrylate. Photopolymerization was measured using Fourier-transform infrared spectroscopy. The morphology of the soft engraved mold and the patterned hybrid film was investigated using scanning electron microscopy.