The Kurt J. Lesker Company is proud to announce the launch of the Pro Line Roll-to-Roll (R2R) Module, a transformative enhancement to the industry-leading Pro Line PVD 200 Thin Film Deposition System. This new, cost-effective, drop-in module brings true roll-to-roll coating capability to the PVD 200 platform, empowering researchers and product developers to bridge the gap between laboratory-scale experimentation and scalable pilot production of flexible electronic devices.
Revolutionizing Thin Film Deposition for Flexible Substrates
The Pro Line R2R Module is engineered to meet the rapidly evolving demands of the flexible electronics industry. With support for a wide range of flexible substrates including PET, PEN, PI, and even metal foils—this module enables the deposition of advanced functional materials using the most sophisticated vacuum-based techniques available today, such as:
- Magnetron sputtering (RF, DC, Pulsed DC, HiPIMS)
- Electron beam evaporation
- Thermal evaporation
- Organic material evaporation
- Ion source substrate cleaning or assisted deposition
Key Features:
- Drop-in integration: The R2R module is designed specifically for the PVD 200 vacuum chamber, requiring no major infrastructure upgrades or new system purchases. This allows existing PVD 200 users to add R2R capability quickly and cost-effectively.
- Unmatched accessibility: When outside the chamber, the module and chamber are accessible from at least three sides, greatly simplifying the manipulation of substrate rolls, cathode materials, cleaning, and maintenance.
- Full process control: Seamless integration with the eKLipse™ advanced recipe control and datalogging system ensures precise process automation and repeatability.
- Configurable substrate handling: Supports web widths up to 300 mm (12”) and unwind/rewind roll diameters up to 175 mm (7”), with total tension control for sensitive substrates and custom speed ranges.
- Multisource compatibility: The module accommodates planar and rotary sputtering, e-beam and thermal evaporation, induction evaporation, and low-temperature organic (LTE) sources—enabling multi-material, multi-layer process development.
Technical Specifications at a Glance:
| Feature | Specification |
|---|---|
| Chamber Compatibility | PVD 200 Tall Chamber (19.25” x 20.5” x 36” internal) |
| Web Width | Up to 300 mm (12”) |
| Unwind/Rewind Roll Diameter | Up to 175 mm (7”) |
| Substrate Materials | PET, Mylar, PEN, PI, metal foils, paper, organics |
| Deposition Techniques | Magnetron sputtering, e-beam, thermal, LTE, etc. |
| Tension Control | Fully programmable, suitable for delicate films |
| Process Control | Integrated eKLipse™ HMI, recipe, and datalogging |
| Accessibility | 3-side access outside chamber for easy roll/cathode handling |
Why Roll-to-Roll? The Engine of Flexible Electronics Innovation
Flexible electronics are redefining technology across sectors—from foldable smartphones and wearable biosensors to smart packaging and ultra-thin batteries. These applications demand not only new materials and device architectures but also scalable, cost-effective manufacturing solutions. Roll-to-roll vacuum deposition is the only viable path for high-throughput production of these devices, enabling continuous coating of functional materials onto moving flexible substrates at speeds and uniformities unattainable by batch processes.
Emerging applications include:- Wearable health sensors and smart textiles
- Flexible OLED/PLED displays and lighting
- Printed batteries and supercapacitors
- Smart labels and electronic packaging
- Stretchable medical devices and electronic skin
The diversity of these applications requires a highly adaptable R2R platform—one that supports a broad range of materials, substrate types, and deposition techniques, while maintaining the precision and cleanliness demanded by advanced electronics manufacturing. .
Bridging the Gap: From Lab to Pilot Production
Traditional R2R systems are often large, expensive, and optimized for mature, high-volume processes. In contrast, the Pro Line R2R Module is purpose-built for R&D and pilot-scale production, offering:
- Maximum flexibility: Easily switch between substrates, materials, and deposition sources for rapid process development.
- Scalability: Develop and optimize processes on planar substrates, then seamlessly transition to R2R coating without purchasing a new system.
- Cost-effectiveness: Leverages high-volume components and proven PVD 200 infrastructure, making R2R capability accessible to research labs and startups at a fraction of the cost of bespoke systems.
“The most positive feedback we received at SVC 2025 was the realization that a development system for materials can be converted into a R2R development system without the need for a completely new system or additional infrastructure. This is a game changer for labs and startups looking to scale up flexible electronics processes.” — Feedback from SVC 2025 TechCon presentation
Configurable for the Future
The PVD 200 R2R Module is not a retrofit for other manufacturers’ systems—it is a purpose-built enhancement for the Lesker PVD 200 platform, ensuring optimal integration and performance. Its modular design supports:
- Planar and rotary magnetron sputteringfor metals, oxides, and nitrides
- E-beam and thermal evaporation for metals, organics, and multilayer stacks
- Induction evaporation and low-temperature organic deposition for sensitive materials
- Ion source cleaning and assisted deposition for advanced interface engineering
This flexibility is critical for developing next-generation devices that require multi-material, multi-layer architecture such as transparent electrodes, barrier coatings, and hybrid organic/inorganic stacks.
Seamless Integration with the Proven PVD 200 Platform
The PVD 200 is a globally recognized, robust, and versatile thin film deposition system, with over 500 units in service worldwide. Key features include:
- Modular 304L stainless steel chamber with O-ring sealed side plates for maximum upgradeability
- Up to 8 sputter cathodes or combinations of e-beam, thermal, and organic evaporation sources
- Substrate heating up to 850°C or water cooling
- Advanced vacuum pumping options (turbomolecular or cryogenic) for base pressures down to 9 x 10-7 torr for a properly conditioned chamber.
- PC-based eKLipse™ control for recipe automation and data logging
- CE, CSA, and NRTL certifications for global compliance
The R2R module’s full integration into the PVD 200’s envelope and control system ensures that users benefit from the same reliability, safety, and process precision that the Lesker name guarantees.
Driving the Flexible Electronics Revolution
Industry trends are clear: Consumer demand for mobility, comfort, and new device form factors is accelerating innovation in flexible electronics. The convergence of printed and vacuum-deposited electronics, the need for ultra-thin energy storage, and the emergence of stretchable and biodegradable devices all point to a future where R2R vacuum deposition is essential. The PVD 200 R2R Module is designed to be the test bed for tomorrow’s breakthroughs:
- Multi-material, multi-layer capability: Develop complex device stacks for displays, sensors, and batteries.
- Multi-substrate handling: Explore new materials, from plastics to bio-based films.
- Precision process control: Achieve the uniformity and reproducibility required for commercial success.
- Rapid iteration: Quickly adjust process parameters, switch materials, and scale up from planar to R2R without disruption.
Empowering Innovation, Accelerating Scale-Up
The Kurt J. Lesker Pro Line PVD 200 R2R Module is more than a hardware upgrade—it is a strategic enabler for organizations seeking to lead in the flexible electronics revolution. By providing a cost-effective, highly configurable, and fully integrated R2R solution, Lesker empowers researchers, startups, and manufacturers to:
- Accelerate materials and process development
- Seamlessly transition from lab-scale to pilot-scale production
- Reduce capital expenditure and infrastructure requirements
- Stay ahead of the competition in a rapidly evolving market
The future of electronics is flexible. With the Pro Line PVD 200 R2R Module, that future is now within reach.
For more information, technical details, or to schedule a demonstration, contact the Kurt J. Lesker Company’s technical sales team.