Quasi-seamless stitching for large-area micropatterned surfaces enabled by Fourier spectral analysis of moiré patterns
Abstract The main challenge in preparing a flexible mold stamp using roll-to-roll nanoimprint lithography is to simultaneously increase the imprintable area with a minimized perceptible seam. However, the current methods for stitching multiple small molds to fabricate large-area molds and functional...
| Main Authors: | , , , , , , , , , |
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| Format: | Article |
| Language: | English |
| Published: |
Nature Portfolio
2023-04-01
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| Series: | Nature Communications |
| Online Access: | https://doi.org/10.1038/s41467-023-37828-8 |
| _version_ | 1797840964106059776 |
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| author | Woo Young Kim Bo Wook Seo Sang Hoon Lee Tae Gyung Lee Sin Kwon Won Seok Chang Sang-Hoon Nam Nicholas X. Fang Seok Kim Young Tae Cho |
| author_facet | Woo Young Kim Bo Wook Seo Sang Hoon Lee Tae Gyung Lee Sin Kwon Won Seok Chang Sang-Hoon Nam Nicholas X. Fang Seok Kim Young Tae Cho |
| author_sort | Woo Young Kim |
| collection | DOAJ |
| description | Abstract The main challenge in preparing a flexible mold stamp using roll-to-roll nanoimprint lithography is to simultaneously increase the imprintable area with a minimized perceptible seam. However, the current methods for stitching multiple small molds to fabricate large-area molds and functional surfaces typically rely on the alignment mark, which inevitably produces a clear alignment mark and stitched seam. In this study, we propose a mark-less alignment by the pattern itself method inspired by moiré technique, which uses the Fourier spectral analysis of moiré patterns formed by superposed identical patterns for alignment. This method is capable of fabricating scalable functional surfaces and imprint molds with quasi-seamless and alignment mark-free patterning. By harnessing the rotational invariance property in the Fourier transform, our approach is confirmed to be a simple and efficient method for extracting the rotational and translational offsets in overlapped periodic or nonperiodic patterns with a minimized stitched region, thereby allowing for the large-area and quasi-seamless fabrication of imprinting molds and functional surfaces, such as liquid-repellent film and micro-optical sheets, that surpass the conventional alignment and stitching limits and potentially expand their application in producing large-area metasurfaces. |
| first_indexed | 2024-04-09T16:23:24Z |
| format | Article |
| id | doaj.art-ec04bf06fbaa474a96951786c8106cce |
| institution | Directory Open Access Journal |
| issn | 2041-1723 |
| language | English |
| last_indexed | 2024-04-09T16:23:24Z |
| publishDate | 2023-04-01 |
| publisher | Nature Portfolio |
| record_format | Article |
| series | Nature Communications |
| spelling | doaj.art-ec04bf06fbaa474a96951786c8106cce2023-04-23T11:21:24ZengNature PortfolioNature Communications2041-17232023-04-011411910.1038/s41467-023-37828-8Quasi-seamless stitching for large-area micropatterned surfaces enabled by Fourier spectral analysis of moiré patternsWoo Young Kim0Bo Wook Seo1Sang Hoon Lee2Tae Gyung Lee3Sin Kwon4Won Seok Chang5Sang-Hoon Nam6Nicholas X. Fang7Seok Kim8Young Tae Cho9Department of Smart Manufacturing Engineering, Changwon National UniversityDepartment of Smart Manufacturing Engineering, Changwon National UniversityDepartment of Smart Manufacturing Engineering, Changwon National UniversityDepartment of Smart Manufacturing Engineering, Changwon National UniversityDepartment of Flexible & Printed Electronics, Korea Institute of Machinery and MaterialsDepartment of Nano Manufacturing Technology, Korea Institute of Machinery and MaterialsDepartment of Mechanical Engineering, Massachusetts Institute of TechnologyDepartment of Mechanical Engineering, Massachusetts Institute of TechnologyDepartment of Smart Manufacturing Engineering, Changwon National UniversityDepartment of Smart Manufacturing Engineering, Changwon National UniversityAbstract The main challenge in preparing a flexible mold stamp using roll-to-roll nanoimprint lithography is to simultaneously increase the imprintable area with a minimized perceptible seam. However, the current methods for stitching multiple small molds to fabricate large-area molds and functional surfaces typically rely on the alignment mark, which inevitably produces a clear alignment mark and stitched seam. In this study, we propose a mark-less alignment by the pattern itself method inspired by moiré technique, which uses the Fourier spectral analysis of moiré patterns formed by superposed identical patterns for alignment. This method is capable of fabricating scalable functional surfaces and imprint molds with quasi-seamless and alignment mark-free patterning. By harnessing the rotational invariance property in the Fourier transform, our approach is confirmed to be a simple and efficient method for extracting the rotational and translational offsets in overlapped periodic or nonperiodic patterns with a minimized stitched region, thereby allowing for the large-area and quasi-seamless fabrication of imprinting molds and functional surfaces, such as liquid-repellent film and micro-optical sheets, that surpass the conventional alignment and stitching limits and potentially expand their application in producing large-area metasurfaces.https://doi.org/10.1038/s41467-023-37828-8 |
| spellingShingle | Woo Young Kim Bo Wook Seo Sang Hoon Lee Tae Gyung Lee Sin Kwon Won Seok Chang Sang-Hoon Nam Nicholas X. Fang Seok Kim Young Tae Cho Quasi-seamless stitching for large-area micropatterned surfaces enabled by Fourier spectral analysis of moiré patterns Nature Communications |
| title | Quasi-seamless stitching for large-area micropatterned surfaces enabled by Fourier spectral analysis of moiré patterns |
| title_full | Quasi-seamless stitching for large-area micropatterned surfaces enabled by Fourier spectral analysis of moiré patterns |
| title_fullStr | Quasi-seamless stitching for large-area micropatterned surfaces enabled by Fourier spectral analysis of moiré patterns |
| title_full_unstemmed | Quasi-seamless stitching for large-area micropatterned surfaces enabled by Fourier spectral analysis of moiré patterns |
| title_short | Quasi-seamless stitching for large-area micropatterned surfaces enabled by Fourier spectral analysis of moiré patterns |
| title_sort | quasi seamless stitching for large area micropatterned surfaces enabled by fourier spectral analysis of moire patterns |
| url | https://doi.org/10.1038/s41467-023-37828-8 |
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