XRD Nano (XRD), a technology company based in the UK, is driving breakthrough innovations in the world of UV replication, focusing on nano and microstructures. Its solutions are being recognised globally, particularly in holographic packaging, transfer films, brand protection labels, shrink sleeves, security documents, and functional films. This article explores the key innovations from XRD that are transforming these industries.
XRD specialises in highly precise UV casting technology for replicating nano and microstructures. Its solutions portfolio includes advanced machines, UV resins, and nano inks, enabling the creation of intricate holographic and light-reflecting structures with exceptional clarity, brightness, and detail.
Key innovations include:
1.Seamless cylinder technology – which allows the replication of nano and microstructures (ranging from 50nm to 50 microns) without any visible seams or joints.
This technology is designed to integrate seamlessly with existing UV embossing and casting lines, making it ideal for long- run productions of 50,000-150,000 linear meters. It ensures consistent quality and improved brightness and reduces tooling costs while operating at speeds of up to 200m per minute.
2.High speed UV casting machines – available in standard widths of 1,650mm and 1,350mm, with options for customisation. They can cast nano and microstructures in R2R from 0.1-50 microns on transparent films from 8 microns onwards. Users can choose single or multiple casting stations and select from various coating methods, including flexo and gravure, as well as curing options like mercury or LED.
3.UV recombination technology – which delivers precise image placement with accuracy +/-5 microns. It features an innovative combiner head with a rotation function and a computer-controlled UV resin micro-dosing system. This technology can be customised to meet specific production needs and supports active areas up to 2,000mm x 1,000mm. The latest version of this technology offers step accuracy of 1 micron, thanks to a new gantry from Aerotech.
4.Nano inks and UV resins – In addition to advanced machines, XRD has developed a range of specialised nano inks (inline metallisation inks) and UV resins for high-speed replication, casting, and printing. These materials ensure the high-quality replication of nano and microstructures, enhancing both the appearance and security features of the final product.
The environmentally friendly UV resins and formulations are designed to integrate smoothly with XRD Nano’s equipment, allowing customers to begin production immediately without creating custom materials.
5.Research and development (R&D) equipment – XRD has also developed machinery for R&D and pilot lines. One notable innovation is a 200mm wide roll-to-roll laboratory UV embosser with a compact design that still mirrors full- scale production processes.
Good for R&D and pilot production, this machine allows users to quickly test new features, substrates, and resins using either nickel or polymer shims at speeds of up to 100m per minute with interchangeable LED or Mercury arc UV curing lamps.
According to XRD, its commitment to innovation has established the company as a key player in the UV replication and casting industry. ‘As XRD continues to push the boundaries of UV replication technology, it is well-positioned to contribute further to the industry and these fields’, the company said.
For more information, visit www.xrdnano.com or contact guri@xrdnano.com.
