<title>Dry photopolymer embossing: novel photoreplication technology for surface relief holographic optical elements</title>

Abstract

Novel photoreplication technology for deep groove surface relief holographic optical elements (HOE) was developed recently at Du Pont. Dry photopolymer embossing (DPE) technology utilizes Du Pont proprietary materials and processes to replicate precisely almost any kind of surface relief or embossed holograms. Very sophisticated surface relief holograms with the high width/depth aspect ratio of 1:20 can be faithfully replicated by this technology. Dimensions of the replicated grooves or other surface relief structures vary from 0.1 micrometers to 3.5 micrometers . Such HOEs can be produced in different geometrical configurations and sizes, which are actually dictated by the master hologram. Embossed HOEs can be fabricated on a plastic film or sheet substrate of different types, thicknesses, and shapes. Glass and other inorganic materials can be also used as substrates in some applications. To replicate such deep groove surface relief HOEs, the master hologram should be recorded in metal, glass, or other hard surface material. DPE technology may provide substantial technological and economical advantages over existing conventional replication processes, such as thermo-embossing, injection molding, wet photopolymerization (2P-process), and injection-reaction molding, in replication of different types of surface relief HOEs.