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WFT's embossing capabilities are wide reaching. Micro-Structured features are used to control light from simply bending light in one direction or diffuse light in a controlled manner or to create a complicated 3 dimensional image. We can replicate features as small as a few nanometers to over 150 microns in height. We emboss rolls of film product from 6" to 68" wide with thickness of 12.5 microns to 300 microns. WFT's Proprietary Tooling technology allows us to obtain shorter job turnaround with a degree of complexity possessed by few other embossers in the world. We can produce replicated structures with nearly vertical walls for application not typically serviced by a roll to roll production process which can deliver large volumes of product at economical prices. We can design your structure, originate it, tool it for mass production, and produce rolls ready for converting. Once a structure has been replicated WFT has the capability to bond the film to a Rigid plate cut to size, all in-house. WFT is a one-stop producer for all your micro-structure replication needs.
WFT has the capability of originating many forms of microstructures. We have in-house Diamond Turning, Holographic, and Lithographic origination capabilities. We can also run customer provided micro-structures.
WFT has become a fully integrated facility with the ability to originate your Diamond Turned Machined (DTM) structure, produce product of the structure in a R2R process, metallize it if necessary and finish it, completely in-house. WFT's new Diamond Turning Facility is an ultra-precision diamond machining lab. The materials that are currently machined are Acrylic, Brass, Copper and Nickel. Many types of Molds can be produced in this lab. These Molds are then turned into embossing tools used on a UV casting machine to replicate the structure onto a film substrate. The types of cuts that can be made for tool/mold fabrication include: Cylindrical Drum tools, Flat faced mold tools and Fly-cut tools for exotic and deep aspect ratio films. The types of Patterns that can be cut include: Grooves (prism and truncated prism structures), Grooves that have a new angle on each cut and valleys with rounded tip radii up to virtual dead sharp notches. At WFT, molds can be manipulated after cutting. The shape can be changed or textured in a way that diamond turning alone cannot achieve.
Wavefront's Holographic capabilities are a result of years working on industrial applications employing Holographic Optical Elements (HOE's). These were used for applications like linear and rotary encoders, back-plane reflectors for lighting application, telecom elements, etc. Our recording facility has produced the largest diffraction gratings in the world to meet the highest demands of the package industry. This lab is capable of originating HOE's, Diffraction Gratings, and Holographic Diffusers (TMD®).
Our Grayscale lithography lab is capable of originating microstructures with freeform shapes up to 8" square. Depths can vary from submicron to 20 microns.
Our Proprietary Tooling has been developed over the last 25 years. WFT provides tooling to the holographic embossing industry and is known for rapid turnaround and high quality. This tooling technology allows WFT to combine microstructures (Step and Repeat) starting from as small as 0.25" to as large as 48" x 72". With this technology, WFT was able to decrease the turnaround time in the holographic embossing industry from what use to take 3 weeks to as little as 1 day.
WFT employs the same technology with DTM structures such as Prisms. Unlike other manufacturers of prismatic films who run directly off a DTM cylinder, WFT makes master tooling from the DTM cylinder. We then combine the prism structure into panels which size is dependent on the final product. This allows us to build a tooling tree that we rely on to continue a product line for many years. Instead of having to re-cut a cylinder when an image wears out or gets damaged, we only go back 1 generation and make a new tool which is used to make the product. This is a cost-effective method which allows for a consistent product with a long life.
Production Equipment is custom built in-house and some operated in class 10,000 Clean Rooms. Since the equipment used to make our products is specialized, we had to design it ourselves. WFT has a full machine shop which builds and maintains our equipment. Because it is built here, we have the intimate knowledge that allows us to maintain, repair and improve the equipment. This equipment is proprietary and very specialized and would be difficult for a competitor to duplicate without our many years of experience.
UV formulations used to make our products are mixed in-house. WFT has a UV polymer lab used for R&D and a production mixing facility. WFT has many standard formulations produced in house by mixing the raw materials together. These formulations are used to produce product on our production equipment. We currently produce many different custom formulations depending on the required micro-structured product and required Index. Different structures require different raw materials depending on the specifications of the final product. This in-house ability allows us full control
WFT is a leader in the nanostructure and microstructure industry due to our vast experience with so many different types of micro-structures. We have over 30 years of experience working with microstructures as well as over 20 years producing rolls of product. There are few companies with the experience and ability to originate, tool up, and produce the custom products that WFT can produce.
WFT now introduces RIGID sheet products. Microstructures are replicated to thin PET film substrates on our R2R machines. This film is then bonded to acrylic, polycarbonate, or other substrates. The bonding agent is a UV cured polymer and has no outgassing. Rigid product can be laser cut into various shapes and sizes all in-house.WFT Technology, Inc. (WFT) produces many custom micro-replicated optical films.
Microstructure Characteristics
- Continuous repeating pattern
- Tiny pyramids, ridges, or raised surfaces
- Features sizes of microns or nanometers
- Thousands of features per square cm
Architectures
- Prismatic
- Holographic Diffuser
- Diffractive
- Moth-Eye
- Micro-lens Feature
WFT's micro-structured films are manufactured in a Class 10,000 Cleanroom via a roll to roll process with widths ranging from 6" to 68". For additional information regarding our micro-structured films please contact our sales department at information@wft.bz. |
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