Periodic Reporting for period 1 - HoloShape (Light-driven surface shaping for holographic optical elements)
Reporting period: 2024-02-01 to 2025-07-31
Augmented and Virtual Reality (AR/VR) technologies are expected to play a central role in how people interact with digital content. A challenge in building lightweight, compact and high-performance AR/VR headsets lay in the fabrication of the optical components that guide and shape light toward the user eyes. Diffractive optical waveguides, which rely on nanostructures to bend and distribute light, had emerged as the most promising solution. They offer a thin form factor and high image quality. However, existing manufacturing methods, such as electron-beam lithography and nanoimprint lithography, are costly, time-consuming, and difficult to adapt when new prototypes or design iterations are required. This slows down innovation and keeps prices high.
The HOLOSHAPE project addressed this problem by introducing an approach to fabricating diffractive optical elements using azobenzene materials. The method relies on light-driven surface structuring of azobenzene-containing thin films, where the material reshapes itself at the nanoscale in response to light patterns. A digital holographic microscopy tool developed by the team enables real-time monitoring and feedback control of the structuring process with nanometer precision. This combination makes it possible to write complex patterns directly onto the surface in a single step, as well as to erase and rewrite structures when a design needed to be modified. In this way, prototyping cycles that previously took months could be reduced to days.
The overall objectives of HOLOSHAPE were to validate this fabrication approach, demonstrate its ability to produce high-quality optical components for AR/VR applications, and show that it could be integrated into existing industrial manufacturing workflows. The project also aimed to assess the market potential of the technology, develop an intellectual property strategy, and explore commercialization routes ranging from licensing, parnetship to spin-off activities.
The expected impacts of HOLOSHAPE were significant. Technologically, the project provided AR/VR designers with new degrees of freedom in optical design, including continuous control over the height of surface relief gratings, which had been difficult to achieve with conventional techniques. Economically, it would lower the costs and shorten the time needed for prototyping, accelerating the pace of innovation in AR/VR devices. Environmentally, it reduces the use of toxic chemicals involved in standard etching processes. By addressing both technical and commercial aspects, HOLOSHAPE contributed to a new method of manufacturing affordable and high-performance AR/VR system.
The HOLOSHAPE project addressed this problem by introducing an approach to fabricating diffractive optical elements using azobenzene materials. The method relies on light-driven surface structuring of azobenzene-containing thin films, where the material reshapes itself at the nanoscale in response to light patterns. A digital holographic microscopy tool developed by the team enables real-time monitoring and feedback control of the structuring process with nanometer precision. This combination makes it possible to write complex patterns directly onto the surface in a single step, as well as to erase and rewrite structures when a design needed to be modified. In this way, prototyping cycles that previously took months could be reduced to days.
The overall objectives of HOLOSHAPE were to validate this fabrication approach, demonstrate its ability to produce high-quality optical components for AR/VR applications, and show that it could be integrated into existing industrial manufacturing workflows. The project also aimed to assess the market potential of the technology, develop an intellectual property strategy, and explore commercialization routes ranging from licensing, parnetship to spin-off activities.
The expected impacts of HOLOSHAPE were significant. Technologically, the project provided AR/VR designers with new degrees of freedom in optical design, including continuous control over the height of surface relief gratings, which had been difficult to achieve with conventional techniques. Economically, it would lower the costs and shorten the time needed for prototyping, accelerating the pace of innovation in AR/VR devices. Environmentally, it reduces the use of toxic chemicals involved in standard etching processes. By addressing both technical and commercial aspects, HOLOSHAPE contributed to a new method of manufacturing affordable and high-performance AR/VR system.
HOLOSHAPE showed that light can directly shape azobenzene films into precise optical patterns for future AR and VR headsets. We defined practical grating designs with input from industry, then refined exposure conditions and real time metrology to control height of the grating with nanometer level precision. We proved that designs can be erased and rewritten, which turns long fabrication cycles into fast iteration and supports creative exploration.
We tested reconfiguration on working couplers and introduced small angle corrections to match updated designs. This cut turnaround time, and revealed where stitching and alignment must improve for seamless large areas. We evaluated reproducibility across many samples. Performance was stable at larger periods, while small period deviations tracked back to coating thickness variation from manual deposition. This points to industrial coating such as slot die or roll to roll to achieve uniform films. We outlined upgrades to imaging and feedback to resolve finer structures with confidence.
Finally, we prepared transfer to replication lines so that reconfigurable masters can feed established production. This integration will be the next step.
We tested reconfiguration on working couplers and introduced small angle corrections to match updated designs. This cut turnaround time, and revealed where stitching and alignment must improve for seamless large areas. We evaluated reproducibility across many samples. Performance was stable at larger periods, while small period deviations tracked back to coating thickness variation from manual deposition. This points to industrial coating such as slot die or roll to roll to achieve uniform films. We outlined upgrades to imaging and feedback to resolve finer structures with confidence.
Finally, we prepared transfer to replication lines so that reconfigurable masters can feed established production. This integration will be the next step.
Engagement with potential users indicated interest across three areas. AR and VR developers seek faster iteration on larger substrates. Security stakeholders value difficult to replicate features and tunable appearance. Beam shaping manufactures request higher diffraction efficiency. Common requirements are compatibility with existing processes, evidence of high throughput, and scale up to larger formats.
Identified needs for further uptake are scale and repeatability. Uniform coatings point to industrial deposition methods such as slot die or roll to roll. Improved stitching and grating offset control require higher numerical aperture imaging and stronger feedback algorithms. Materials and process optimization should raise diffraction efficiency for beam shaping cases. Replication of reconfigurable masters by nanoimprint in existing lines needs a full validation with an industrial partner. Continued intellectual property landscaping around reconfigurable masters will support commercialization.
At project end, a plan was prepared to increase technology readiness through an external acceleration programme. Priorities are scale and throughput, industrial coating for uniform films, improved stitching and metrology for small periods, and a replication trial with a manufacturing partner.
Identified needs for further uptake are scale and repeatability. Uniform coatings point to industrial deposition methods such as slot die or roll to roll. Improved stitching and grating offset control require higher numerical aperture imaging and stronger feedback algorithms. Materials and process optimization should raise diffraction efficiency for beam shaping cases. Replication of reconfigurable masters by nanoimprint in existing lines needs a full validation with an industrial partner. Continued intellectual property landscaping around reconfigurable masters will support commercialization.
At project end, a plan was prepared to increase technology readiness through an external acceleration programme. Priorities are scale and throughput, industrial coating for uniform films, improved stitching and metrology for small periods, and a replication trial with a manufacturing partner.