Step 1: Design Structure
Our optics engineers design and create MLA structures with custom in house software.
Step 2: Create Structure
The software design is transferred to a custom grayscale lithography system. Using a raster scanning laser, the MLA structures are patterned pixel by pixel, resulting in a master.
Step 3: Create Tooling
The master is used to create robust tooling. The structure can be reproduced in large quantities using our roll to roll process.
Step 4: Create Final Product
A high-volume roll-to-roll replication process in a clean room environment makes the final product in mass quantities. From these rolls the final product is cut to customer specifications.
Roll-to-Roll Production Process
Incoming roll: PET or polycarbonate film
UV curable photopolymer is applied and embossed, replicating the structure from the tool, shown in light blue around the drum, into the photopolymer
UV light cures the photopolymer
Finished product is re-rolled and ready for converting to final part
Clean Room Production and Inspection
BrightView manufactures and inspects products to the highest quality, to ensure our MLAs will perform in your application. We have hard wall and soft wall cleanrooms, and all manufacturing is contained in class 1000 clean room space. Product from the production line is inspected within the same space.
