Roll-to-Roll Processing

Roll to roll processing is a continuous, low cost manufacturing method used to make materials ranging from newspapers to flexible circuits to polymer photovoltaic cells. PSI can utilize a broad range of R2R equipment, expertise and process control methods to yield formidable pilot scale production.

Image of pilot scale R2R process tanks and film conveyor (left) and a drawing of a continuous nanofiber fabrication, stretch and windup system.

Current activities include development of roll to roll processing of polymer films using silver ink patterning followed by electroless copper deposition. We are fabricating continuous sheets of metal patterns with 100 micron resolution at speeds up to 10 m/min. We are also coating continuous rolls of textiles with an antimicrobial agent that is chemically bound to the fabric surface. This process feeds fabric rolls through three sequential chemical solutions followed by an in line dryer.