Computation and fabrication tools for sub-wavelength texturing of visible and IR surfaces

Large-area, sub-wavelength texturing can convert walls, windows, ceilings, floors, and even vehicles into advanced surfaces that enhance, shield, or manipulate electromagnetic waves. These textures, or “nanopatterns,” enable transformational technologies for warfighter protection and advanced offensive capabilities. Applications include multispectral camouflage, holograms, heads-up displays, and augmented reality, and advancements contribute to the Army’s network of hardware and infrastructure “that can be used in any environment where the electromagnetic spectrum is denied or degraded,” the US Army’s Modernization Priority 4. Despite these benefits, large-area textured surfaces for the control of electromagnetic radiation have yet to see practical implementations. This is because traditional nanopatterning techniques are extremely slow and costly, prohibiting large-area scale-up. Smart Material Solutions, Inc.’s patented technology – nanocoining – overcomes this previously insurmountable obstacle. Nanocoining is hundreds of times faster than competing technologies like electron beam lithography and is unique in its ability to seamlessly nanopattern cylindrical molds for roll-to-roll manufacturing. This project will develop tools to design and fabricate sub-wavelength textures, then use scalable roll-to-roll processes to fabricate a large-area holographic optical element as a demonstration to Army contacts. This advancement will allow a host of revolutionary technologies to transition from the lab-scale demonstrations to large-area production.