Antennas - Interconnects

Acreo has developed a new technology for patterning of flexible materials, such as laminated flex foils. The process, called Dry Phase Patterning (DPP), is based on mechanical machining of the material. The method allows patterning with high precision at high speeds. In a traditional etch process the first step is to print a resist mask. This is followed by the etching step and a third step in which residuals of resists and etch liquids are removed. In the DPP method the pattern definition and the material removal is done in the same step. Furthermore, the residuals from the process is in a dry phase and fully recyclable. Thus, the method has large environmental benefits; no chemicals are used and all removed material is recycled. To pattern fibrous materials or products sensible for fluids or chemicals are not possible with etch based methods, but by using the DPP method it is now possible to realize such products at a very low cost.

The resolution of the pattern is comparable to the resolution of etching; patterns with spacing and lines smaller than 100µm have been demonstrated. Just as for etching, the resolution of the pattern is depending on the patterned material, but the DPP resolution will not decrease with higher production speed. Tests have shown that it is possible to pattern with high precision at speeds exceeding 150 m/min.