Support for ultra-fine process-related products that apply nanoimprint lithography technology from planning to volume production
DNP Nanoimprint Solutions
DNP Nanoimprint Solutions are a new business that employ nanoimprint lithography (NIL) technology to make the link from application development of ultra-fine products and product planning to market creation. Integrated support is provided from planning through development, mold and prototype making, to volume production.
Regarding the trial and examination of micro-machined molds and other shaped products (processed goods with transferred ultra-fine patterning), DNP rises above the level of a prototype contracting business to capitalize on originally developed NIL technology and provide integrated support from application development of ultra-fine process-related products and product planning through mold and prototype making, to volume production, leading to the creation of markets. As the industry’s first full scale integrated line-based ultra-fine processing business, DNP will provide a variety of products, including electronic materials, such as magnetic recording media, light emitting diodes, organic EL, light guiding panels and photovoltaic cells, along with bio- and medical-related materials.
●What is a nanoimprint lithography (NIL) ?
NIL is an ultra-fine processing technology that takes materials formed on a substrate, then seals them with a mold while still soft, before hardening to produce nanometer (10-9 meter) to micrometer (10−6 meter) level patterns in a stable manner. This is also achieved at low cost. Film or quartz glass is used in the substrate, while UV curable resin or thermoplastic resin are used with the transferred materials.
There is growing demand for products in a variety of areas, including optical components for displays, and in bio and medical uses, for components and materials with nm level ultra-fine patterns to facilitate new functions. The challenge remains, however, that research organizations and manufacturers do not maintain the specialist knowledge or technology related to molds or to the manufacturing process when it comes to producing ultra-fine products. Installation costs related to the dedicated facilities at the nm level are also a burden*1.
DNP ventured into the development of NIL technology at an early stage, in response to the miniaturization of semiconductor circuits and electronic equipment. DNP can be proud of the notable achievements it has made in this area, including the production of 10nm level semiconductor circuit pattern molds (templates), and the creation of ultra-low reflective film that prevents light reflection by transferring, and configuring on the surface of a transparent film, hundreds of nm level micro-bumps. And by capitalizing on the experience, know-how and technology developed while creating this track record, it has been possible to roll out an integrated ultra-fine processing business that conducts operations from mold production, which saw major demand from the industry, through the production of prototypes and volume production of end products. At the same time, proposals will also be made for improved mold performance, and in the manufacturing process, in line with product application, and DNP will contribute to a broad set of areas.
*1 In the semiconductor industry area, one business model, referred to as a foundry service, exists where manufacturers may already own high-value manufacturing facilities, and contract only for the manufacture of pre-designed semiconductors. A similar contracting business exists in the area of ultra-fine processing. DNP Nanoimprint Solutions capitalize on their strength of maintaining broad based processing technology. As a result, it has been possible to go beyond mere prototype outsourcing of mold orders from nanometer to micrometer and shaped products, to provide total support from product planning and design to volume production.
● DNP Strengthens Nanoimprint Lithography Template Volume Productions System(2016/6/3) http://www.dnp.co.jp/eng/news/10125509_2501.html
● DNP to Commence Mass-Production of Nanoimprint Lithography Templates for Semiconductors (2015/2/19) http://www.dnp.co.jp/eng/news/10111258_2501.html
● Dai Nippon Printing Branches Out into Regenerative Medicine (nippon.com）(2013/8/30) http://www.nippon.com/en/features/c00514/ (external link)
Service Menu and Features
1. Application developments, proposal-driven planning support and mold design.
2. Production of master molds*2
3. The production of replica molds based on master molds, and production of large-scale molds with an arrangement of multiple replica molds.
4. Production of prototypes with transcribed patterns, and mass production.
The features of the new business are as follows:
● The provision of integrated support from planning, through development, mold production, transcription prototypes to the mass production
● The provision of a broad range of micro patterns from nanometer to micrometer scales.
● The provision, along with the volume production of roll-to-roll molds and products that take large scale roll type film substrates and process them into rolled formats for manufacture and delivery.
● The mass production of products using a variety of DNP-owned manufacturing facilities.
● Support for performance evaluation and improvements to molds in use.
*2: Available master molds: It is necessary to replicate master molds in the post-production stage to offset damage and deterioration through use of transcription molds.
Master molds apply the lithography technology and high precision cutting technology held by DNP, and can be custom-made to order.
1. It is possible to produce ultra-fine patterns of approximately 20nm on the surface of a six inch square substrate, and a master mold with three-dimensional configured patterns.
2. It is also possible to produce a master mold with sub-micron (10 to the minus power of four meters = 10 to the minus power of 7 meters) configured patterns on the surface of a large scale substrate.
3. It is further possible to produce a 1500mm×930mm size mold (roll version or Ballard version) with configured micrometer scale patterns.
4. Prototypes that use these master molds to micro-machine the surface of film or quartz glass, while using the aforementioned master molds, can also be provided.
A broad selection of areas are targeted, such as electronic equipment, optical components, energy, life science
[Anticipated Usage Examples]
●There are expectations for special quality applications with expressions derived from surface fine shaping in the bio and life science areas.
●DNP helps to resolve problems with the production of molds necessary in special shape designs
●DNP has developed a track record in nanometer to micrometer scale molds production, and transcription processing related volume production for optical applications.
DNP will offer this new business model to a broad array of R&D divisions and research institutes for use in research, product development and new business ventures that apply ultra-fine processing technology.
Estimates will be provided on a personalized basis. Client information is treated with the strictest confidence, and none disclosure agreements apply.