PoLaRoll · Project

Ultra-Fast Laser Cutting for High-Speed Roll-to-Roll Production Lines

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Imagine trying to engrave intricate patterns on a ribbon of material flying through a machine at high speed — like writing on a speeding conveyor belt with a laser pointer, except each "dot" lasts less than a trillionth of a second. That's what roll-to-roll laser processing needs to do, and until now the lasers were too slow and the beam steering too imprecise to keep up. PoLaRoll built an ultra-fast laser system with spinning polygon mirrors that can zap patterns on both sides of a moving sheet simultaneously, fast enough to match industrial production speeds. They proved it works by laser-cutting micro-patterns into glass coatings that block solar heat — turning ordinary window film into energy-saving smart shading.

By the numbers

consortium partners

countries involved (BE, DE, FR, IT)

86%

industry ratio in consortium

SMEs in consortium

total deliverables produced

demo deliverables (operating systems)

The business problem

What needed solving

Manufacturers using roll-to-roll production lines cannot currently add precision laser micro-structuring to their process because existing pulsed lasers are too slow and beam steering too inaccurate at production speeds. This forces companies to either use slower batch processing, accept lower precision, or skip laser structuring entirely — missing out on higher-value products like energy-saving solar shading films.

The solution

What was built

The project built a dual polygon scanner laser ablation system using a femtosecond laser with high pulse energy at extremely high repetition rates, capable of processing both sides of web material simultaneously. It also delivered an in-line metrology system for real-time process monitoring, and integrated the complete module into both a prototype roll-to-roll machine and a conventional production machine.

Audience

Who needs this

Glass facade and architectural film manufacturers needing solar shading productsFlexible electronics producers requiring high-speed precision patterningThin-film solar cell manufacturers wanting surface micro-structuring at production speedRoll-to-roll equipment OEMs looking to add laser processing capabilityAutomotive glass suppliers seeking functional coatings with micro-patterns

Business applications

Who can put this to work

Building Materials & Glass Manufacturing

enterprise

Target: Glass facade and window film manufacturers

If you are a glass or facade manufacturer dealing with rising demand for energy-efficient building envelopes — this project developed a laser micro-structuring module that can be integrated into existing roll-to-roll production lines. It creates solar shading patterns directly on glass coatings, reducing the need for separate shading systems. The consortium included 6 industrial partners and built a dual polygon scanner that processes both sides of web material simultaneously.

Flexible Electronics & Printed Circuits

mid-size

Target: Producers of flexible PCBs, OLED displays, or thin-film sensors

If you are a flexible electronics manufacturer struggling with precision patterning at production speed — this project built a femtosecond laser ablation system with dual polygon scanners delivering high pulse energy at extremely high repetition rates. The system was designed for roll-to-roll integration with in-line metrology for real-time process monitoring. With 3 SMEs in the consortium, the technology was developed with scalable manufacturing in mind.

Solar Energy & Photovoltaics

enterprise

Target: Thin-film solar cell and module manufacturers

If you are a solar cell manufacturer looking to improve cell efficiency through surface micro-structuring without slowing your production line — this project delivered a roll-to-roll compatible ultra-short pulse laser system. The polygon scanner technology enables structuring at speeds matching continuous manufacturing. The system was validated on solar shading applications and can be adapted for photovoltaic surface texturing.

Frequently asked

Quick answers

What would it cost to integrate this laser system into our production line?

The project data does not include specific pricing for the laser module. However, the system was designed as a modular unit for integration into existing roll-to-roll machines, which suggests it is intended as an add-on rather than a full line replacement. Contact the coordinator (Fraunhofer) for commercial licensing or system pricing.

Can this scale to full industrial production speeds?

Yes — the entire point of the project was to close the gap between lab-speed laser processing and industrial roll-to-roll throughput. The femtosecond laser was developed with high pulse energy at extremely high pulse rates, paired with polygon scanners for ultra-fast beam deflection. The system was integrated into both a prototypical and a conventional machine operated by an industrial end-user.

Who owns the IP and how can we license it?

Fraunhofer Gesellschaft coordinated the project with 6 industrial partners across 4 countries. IP is likely shared among consortium members under their grant agreement. Fraunhofer has established technology transfer offices — they are typically open to licensing or joint development agreements.

Has this been tested in a real production environment?

Based on available project data, the system was integrated into a conventional machine for mass production operated by an industrial end-user, beyond just the prototypical roll-to-roll machine. Two demo deliverables confirm an operating dual polygon scanner laser ablation system synchronized for roll-to-roll demands.

What materials can the laser system process?

The demonstrated application was solar shading micro-structures on glass facade coatings. However, the technology uses femtosecond laser ablation, which works on virtually any material — metals, polymers, ceramics, thin films — because the ultra-short pulses remove material without thermal damage. Specific material tests would need to be confirmed with the consortium.

How long would it take to deploy this in our facility?

The project ran from 2016 to 2020 and produced a working integrated system. Based on available project data, the modular design was intended to fit into existing roll-to-roll lines. Deployment timeline would depend on your specific line configuration and material requirements. The technology is past the research stage.

Consortium

Who built it

The PoLaRoll consortium is heavily industry-driven: 6 out of 7 partners are industrial (86% ratio), with only Fraunhofer as the research organization — and Fraunhofer itself is known for applied, industry-ready research. The consortium spans 4 countries (Belgium, Germany, France, Italy), giving it a strong Western European manufacturing footprint. With 3 SMEs involved, the project balanced large-company production capability with SME agility. This composition signals a technology developed with clear commercial intent, not an academic exercise. For a business buyer, this means the system was built by people who understand production floor realities.

LASER ENGINEERING APPLICATIONS SAparticipant · BE
LUNOVU GMBHparticipant · DE
SCANLABparticipant · BE
RINA CONSULTING SPAparticipant · IT
AMPLITUDEparticipant · FR

How to reach the team

Fraunhofer Gesellschaft (Germany) — Europe's largest applied research organization with established technology transfer and licensing offices

Order a report on this consortium

Next steps

Talk to the team behind this work.

Want to explore how this ultra-fast laser processing technology could fit your production line? SciTransfer can arrange an introduction to the right people in the consortium and help you evaluate fit.

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