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Amongst the technologies enabling surface structuring at the nanoscale, Ultra-Short Pulse laser (USP) plays a key role when targeting high process robustness, high throughput, and large area processing. In the frame of “Tres Clean” project, texturing of ≈1 m2 surfaces has been recently shown, with the possibility to effectively replicate the nanostructures by injection moulding. Nevertheless, extend USP nanotexturing over several m2 through continuous production represents still an issue due to the need of high-power P, and difficult process control. The “New Skin” project could represent a turning point pushing the readiness of USP-nanotexturing with a significant up-scale of the production volume. Here we show the results obtained with a demonstrative pilot production line based on a roll-to-roll approach and including a 350 W, fs laser and a polygon scanner delivering the beam at scan speed vs < 350 m/s. Line speed values vl are comprised between 3 and 20 mm/s. By systematic variation of some key process parameters (pulse energy and repetition rate) we optimised the nano-structures morphology which has been characterised through FFT and SEM analysis. A throughput of 5 minutes/m2 with an acceptable structure’s quality is reported over several m2 surfaces. Possible applications and values propositions are introduced and discussed.
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