N.C. Scott, L. Micklow, R. McDonald, S. Furst
Smart Material Solutions, LLC,
United States
Keywords: metamaterials, nanotechnology, advanced manufacturing,
Summary:
Advances in metamaterials have enabled unprecedented control over light-matter interactions. However, most demonstrations remain constrained to the lab scale because traditional fabrication methods – which were designed for small, expensive devices like microchips – are incompatible with low-cost manufacturing of large-area nanopatterns. Smart Material Solutions (SMS) addresses this challenge through an advanced manufacturing platform designed specifically for high-throughput nanofabrication. At the core of this manufacturing platform is nanocoining, a high-speed process that seamlessly nanopatterns cylindrical molds for roll-to-roll (R2R) processes hundreds of times faster than electron-beam lithography. When combined with R2R nanoimprint lithography, this process enables continuous fabrication of functional metamaterial films over large areas, removing a key barrier to commercialization. This work presents two categories of metasurfaces enabled by this scalable approach. First, we describe infrared metasurfaces engineered with spatially varying emissivity to conceal objects in the infrared by adding natural patterns that obscure sharp edges. We also demonstrate light-trapping coatings that increase the efficiency of solar panels by redirecting light into the panels while also adding self-cleaning properties that prevent soiling.