APPLICATIONS
Recombining
The recombination stage addresses a fundamental challenge in holographic production: the lithography machine produces individual master images at a specific size, but commercial printing and packaging applications require the optical effect to be repeated across much larger areas with precise registration. Recombining, also known in the industry as step-and-repeat, is the process of multiplying the single master image from the glass master onto a larger format.
Creating PET Master and Large Format Plate Assembly
The recombination process begins by first creating a PET (polyethylene terephthalate) film master from the glass master. The micro-structured glass plate is used as a template to emboss the holographic image onto a thin PET film substrate. This PET film now carries a negative impression of the original glass master pattern.
The PET master is then mounted on a precision recombination machine. Using a step-and-repeat mechanism, the machine precisely positions the PET master and sequentially presses it onto a larger PET substrate in a regular grid pattern. Each impression is aligned with sub-millimeter accuracy relative to adjacent impressions. The recombination process can create large-area masters up to dimensions of 600 x 1500 millimeters, depending on the embossing equipment specifications.
During recombination, several technical parameters must be carefully controlled: registration accuracy (typically within 0.05 millimeters), consistent pressure across each impression, uniform temperature to ensure clean pattern transfer, and precise gap control between adjacent impressions. The recombination machine's software allows operators to configure the step distance, overlap settings, angular orientation, and arrangement pattern (including staggered, reverse, or blank options) to optimize the layout for the client's specific printing and packaging requirements.
The output of this stage is a large-format recombined PET master plate containing multiple repetitions of the original holographic image, precisely arranged and ready for the electroforming process. This large plate will eventually become the source from which working nickel shims are produced for high-volume embossing production.
