Maintaining the fidelity during mass production of nanostructures over large surface areas poses several challenges. Thin polymer optic components are susceptible to warping, birefringence, and errors in nanostructure form and periodicity. These issues can vary across the entirety of the surface, much more than in smaller injection molded parts. We discuss some of these challenges, their effects on the performance of the nanostructures, and some methods for mitigation.
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