The primary goal of the EU-funded "Phabulous" project was to establish a European pilot line infrastructure equipped with cutting-edge manufacturing technology for the production of freeform micro-optics. This infrastructure aims to accelerate innovation and production cycles from prototyping to large-scale production.

Special attention in the project was paid to the large-scale replication of micro-optical structures in roll-to-roll systems. The collaboration between the project partners Fraunhofer FEP and JOANNEUM RESEARCH Forschungsgesellschaft mbH from Austria played a major role in the explicit research of this technology.

The researchers combined several processes: nanoimprint lithography, coating technologies and plasma etching. This allows structures of different sizes to be produced. The dimensions range from a few nanometers to a few micrometers – therefore, the structures are much thinner than a human hair. During the course of the project, several applications have already been worked on with external industrial partners. These were aimed at a wide range of issues and ranged from improving the efficiency of solar cells to creating decorative effects.

Furthermore, the use of roll-to-roll technology also opens up scaling options on an industrial scale. This will also make it possible to achieve cost reduction effects in the production of a wide range of micro-optics on film substrates in the future.

New applications beyond the project boundaries

At Fraunhofer FEP, the researchers used the knowledge gained in the project as well as their extensive expertise in roll-to-roll technology and the development of specialized coating processes to achieve further advances in the use of such microstructures beyond the project.

Dr. Matthias Fahland is delighted with the implementation of a new application: “We have achieved a great success in the development of a new type of bird protection film. By equipping polymer films with micro-optical structures in a roll-to-roll process, we have achieved an optical appearance that differs significantly from that of unprocessed polymer films. By attaching them to glass facades, birds can recognize the surfaces better and thus avoid collisions. The special feature here is that the contrast visible to humans is only slight, as the polymer films differ primarily in the ultraviolet spectral range, to which the human eye is insensitive; birds, on the other hand, can clearly perceive the difference.”

This ensures a reliable effect as a bird protection film in different light conditions. This new solution also offers advantages thanks to its almost full-surface transparency, which only has a minimal aesthetic impact on the architecture.

Future prospects

The scientists at Fraunhofer FEP are now striving to further develop this technology. It opens up a wide range of new application possibilities, particularly in the design of large glass surfaces in the building and architecture sector. For further improvement, the Fraunhofer researchers are relying on future collaboration with ornithologists and manufacturers of special films and are looking forward to a lively exchange and in-depth discussions.

The jointly achieved results of the “Phabulous” project as well as first examples of the generated microstructures for use as bird protection films will be presented at the Micro-Optics Summit from December 2 – 3, 2024 in Amsterdam during the exhibition and conference.

In addition, Fraunhofer FEP will present the results at BAU 2025, from January 13 – 17, 2025 at the Fraunhofer joint booth no. 528 in Hall C2, to discuss and promote the further development of these polymer films with potential partners.

About the project Phabulous

Phabulous – Pilot-line providing highly advanced & robust manufacturing technology for optical free-form micro-structures
Funding authority: European Union
Grant agreement no.: 871710
Project duration: 01.01.2020 - 31.12.2024
Website: www.phabulous.eu

This project has received funding from the European Union’s Horizon 2020 research and innovation program under the Grant Agreement nº 871710, in Public Private Partnership with Photonics 21 (www.photonics21.org).

Fraunhofer FEP at the Micro Optics Summit 2024

December 2 – 3, 2024
Amsterdam, The Netherlands
www.microopticssummit.com

Fraunhofer FEP at the trade fair BAU 2025

January 13 – 17, 2025
Munich Trade Fair Center, Munich, Germany
Fraunhofer Joint Booth, hall C2, booth no. 528
Further information: www.fep.fraunhofer.de/bau