Reported is the manufacture and optimization of inverted micropyramid cavity structures into thermoplastic sheets using roll-to-roll (R2R) embossing. To manufacture the master, an ultraprecision diamond machining method was applied to create seamless surface structures into a copper-coated hot embossing roller. Using the hot embossing process, the roller features were successfully transferred to 2 mm thick polymethyl methacrylate (PMMA) sheets. Optimization of the R2R control process variables was conducted using Taguchi's numerical methods, which showed the importance of the roller temperature for a successful pattern transfer. The work presents a novel fabrication technique that allows microstructures to be manufactured into thick PMMA sheets in a continuous process.

中文翻译：

---

用于制造热塑性片材微金字塔结构的连续热压印工艺的优化

据报道，使用卷对卷 (R2R) 压花将倒微锥腔结构制造和优化为热塑性片材。为了制造母版，采用超精密金刚石加工方法在镀铜的热压印辊中创建无缝表面结构。使用热压印工艺，辊子特征成功地转移到 2 毫米厚的聚甲基丙烯酸甲酯 (PMMA) 片材上。R2R 控制过程变量的优化是使用田口的数值方法进行的，这表明辊温度对于成功的图案转移的重要性。这项工作提出了一种新颖的制造技术，允许在连续过程中将微结构制造成厚的 PMMA 板。