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Roll-to-roll electronics

• Sep 29, 2009 •

The roll-to-roll manufacturing process step by step, as seen at Binghamton’s Center for Advanced Microelectronics Manufacturing.

  • Camm1

    A roll of new material arrives and is inspected for surface particulates, scratches or other imperfections.

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    The material is cleaned.

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    The roll is inspected again to verify the cleaning process.

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    The roll goes to the General Vacuum tool for metallization. The machine precleans (or “wets”) the surface just before coating to improve the adhesion of the metal.

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    In the resist-apply phase, a photoresist material is applied with a spray system or through a slot-die wet coating. Now there’s an ultraviolet-sensitive roll of material ready to be exposed, much like a roll of film. The material goes through a projection lithography system, which can expose up to 24 linear inches per minute of web.

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    The material goes through a developer and is rinsed and dried. The material is etched, removing the exposed metal that’s not needed. A stripping process removes the remaining photoresist material.

  • Camm7

    The metal-patterned roll of material is ready. Possible applications include smart fabrics, sensors and medical devices as well as consumer electronics.

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