Roll-to-roll manufacture of microstructured metamaterials films

Physical Sciences, Inc. (PSI) will demonstrate the rapid prototyping and roll-to-roll (R2R) fabrication of microscale copper metal on dielectric polymer film based metamaterial (MTM) architectures during the proposed Phase II program. We will calculate a broad range of optimized RF attenuators by tuning our microscale MTM geometry and properties. We will then fabricate a range of radio frequency (RF) absorbing MTM films providing at least 99% attenuation at the selected design frequencies. The versatile MTM will provide broad or narrow band attenuation. During the Phase I program PSI demonstrated the low cost, rapid MTM architecture production on a small scale and verified the performance of our unique design via RF testing with an NRL arch configuration. We also showed a 12"wide R2R process for patterning the substrate with the unique MTM architecture. We expect to demonstrate batch fabrication of 24"by 24"prototype MTM panels on the Phase I Option program. During the proposed Phase II Base program, we will construct a 24"wide continuous R2R process for the MTM fabrication. On a Phase II Option PSI will package the MTM to demonstrate the environmental and mechanical stability required for shipboard topside use.