Multi‐objective optimization in roll‐to‐roll <scp>UV</scp> embossing for manufacturing linear Fresnel lenses

Abstract Linear Fresnel lenses are widely used in solar energy concentration, image processing, and optical imaging applications. Concentrated solar power technology offers a more efficient and economical solution by focusing sunlight onto a smaller receiver, thereby increasing energy conversion efficiency and reducing facility costs. This research aims to design and manufacture a concentrating lens that can achieve the most uniform illumination and the lowest energy loss percentage. The optical design of the linear Fresnel lens aims for maximum uniformity and minimal energy loss. The lens parameters include a lens area, a focal length, and a structure spacing. Roll‐to‐roll UV embossing was applied to produce the linear Fresnel lenses. Four embossing parameters: resin pressure, film speed, film‐press pressure, and film tension, were optimized. The design optimization uses the Taguchi method and multi‐objective response surface methodology (RSM), which are applied to the optical design and process parameter analysis. The results show that optimized parameter combinations can significantly improve the replication percentage of the lens structure and reduce surface bubble defects. In addition, the linear Fresnel lens was tested on solar cells. The highest quality lenses are manufactured under multi‐objective optimization conditions. Highlights Multi‐objective optimization design using response surface methodology. Applying linear Fresnel lenses to solar cells increases output power. Optimized Fresnel lens design achieves uniform illumination and low energy loss. Roll‐to‐roll UV embossing makes Fresnel lenses with excellent light focus.