This article is based on an original interview published by Techblitz. The content has been translated from Japanese into English for accessibility purposes. The original version, published on April 23, 2026, explores Morphotonics’ role in advancing nanoimprint technology for next-generation AR and optical applications.
Breaking Through the Limits of Nanoimprint Technology with Flexible Thinking
As AI continues to advance, AR devices in the form of smart glasses and glasses-free 3D display technologies are becoming increasingly realistic. To enable these next-generation devices, nanoimprint technology is essential.
However, conventional nanoimprint technology is based on wafer-level processing designed for semiconductors. This makes it extremely difficult to transfer patterns onto large glass substrates, such as those required for AR glasses, in a single process. As a result, even when high-quality prototypes exist, the major hurdle of commercial-scale mass production has remained.
The Dutch company Morphotonics is working to overcome this challenge. Instead of using rigid molds, the company has developed a unique approach that uses flexible stamps mounted on rollers, ensuring uniform contact across large surfaces. This approach achieves what was previously considered impossible: both large-area processing and ultra-high precision nano-level fabrication. As a result, Morphotonics can manufacture next-generation optical components at speeds that surpass conventional systems, and has already delivered equipment to manufacturers in the United States and Asia.
We spoke with CEO, Hugo da Silva, who joined the company in late 2024 after holding key roles at Philips and DOW Corning, about the challenges Morphotonics is addressing as it builds the “invisible infrastructure” behind AR devices.
What problem is Morphotonics trying to solve?
As AI now enables real-time conversion of 2D content into 3D, demand for glasses-free 3D displays is rapidly increasing. At the same time, AR smart glasses are becoming smaller and more practical, with waveguide image transmission emerging as the dominant approach.
This technology requires extremely fine nanostructures on optical surfaces. However, until now, there has been no way to manufacture these structures with high precision on large substrates. The result has been a situation where prototypes can be made, but mass production is not feasible.
Traditional nanoimprint technology is based on circular semiconductor wafers, making it unsuitable for the large glass substrates required for displays. In other words, manufacturing infrastructure has not kept pace with the rapid evolution of AI-driven devices.
Our goal is to bridge this gap by delivering both high precision and scalability, and to become a key part of the manufacturing infrastructure for AR devices in the AI era.
Can you explain your “R2P nanoimprint” technology?
Our technology is based on a Roll-to-Plate (R2P) nanoimprint process, using a flexible stamp wrapped around a roller.
The process works as follows:
- A UV-curable resin is applied to the substrate
- The flexible stamp is pressed onto the surface
- UV light cures the resin, transferring the nanostructure
Unlike traditional wafer-based systems, which process one wafer at a time, our roll-based method allows for continuous processing of large-area substrates. This makes it possible to manufacture large optical components and process multiple areas simultaneously.
While the concept is similar to compression molding used in LED manufacturing, the key innovation lies in the use of a flexible stamp, which enables both high precision and large-area scalability.
Do you have examples of real-world implementation?
Due to NDAs, we cannot disclose all details, but we can share a few examples. We have a publicly announced partnership with Leia, a U.S.-based 3D display company. They initially adopted our Portis system and have since transitioned to fully automated mass production using Aurora. In the AR waveguide space, a U.S. company has already begun mass production using our equipment. We have also received an order for our latest system, Cypris, from an Asian contract manufacturer, which will be used to produce components for a major U.S. brand.
Additionally, products manufactured using our technology are already on the market through major TV manufacturers in South Korea and China.
Can you tell us about your background and how you joined Morphotonics?
I grew up in Brazil and started my career as an electronics engineer. My first role was at a joint venture between Toshiba and a Brazilian consumer electronics company, working on televisions and related products.
I later joined Philips Lighting (now Signify), where I spent about ten years in roles spanning product development, marketing, and sales, both in Brazil and the Netherlands. One key milestone was my involvement in launching LED lighting in the Netherlands.
After that, I joined Dow Corning (now part of Dow), where I built an optical materials business for displays and solar applications from the ground up. During this time, I worked closely with Japan, particularly through collaborations with Dow Corning Toray.
I then moved to DSM, where I built a 3D printing business, and later joined Stratasys as VP, focusing on strategy, M&A, and startup scouting.
I was invited to join Morphotonics because the founding team had strong technical expertise but needed leadership with commercial and international experience to scale the business. After evaluating the technology and market potential, I became CEO in October 2024, convinced that Morphotonics could become a key manufacturing enabler in the rapidly growing AI device market.
How has the business evolved since you became CEO?
One of my first priorities was to narrow the company’s focus. Nanoimprint technology has many potential applications, which can dilute resources. We therefore concentrated on two key areas:
- AI Glasses
- Advanced display technologies (including glasses-free 3D)
At the same time, we strengthened our sales and marketing capabilities, which had previously been underdeveloped. In 2025, we opened an office in China and built a dedicated team in the United States. These efforts paid off: in 2025, we achieved record revenue, growing 3–4× year-over-year.
We are also building a network of contract manufacturers equipped with our systems. Currently, we have facilities in Singapore and Germany, and are expanding into the United States. This allows customers who cannot invest in their own equipment to still access our technology.
What is your main focus for 2026?
We are now preparing for mass production of our new system, Cypris. Initial units have already been delivered for testing, and we are in the final stages of development.
Our goal is to complete shipments to several customers by the end of the year and move into full-scale mass production in 2027.
On the funding side, we plan to close an additional Series B round in April–May 2026, securing the capital needed for the next phase of growth.
What is your strategy for the Japanese market?
Japan is a highly strategic market for us.
It is home to key suppliers of:
- High refractive index substrates used in waveguides
- Advanced materials, including imprint resins
We are already collaborating closely with Japanese partners. In addition, we see strong opportunities for investment and M&A, particularly with Japanese equipment manufacturers looking to expand into microfabrication and AR technologies.
As we expand further into Asia, we are also considering establishing a permanent presence in Japan in the near future.
Where do you see Morphotonics in 5–10 years?
Over the next three years, our focus is on scaling the AR waveguide market. According to industry forecasts, the AR glasses market could reach 100 million units by 2030, requiring at least 200 million waveguides.
We believe we are currently the only company capable of delivering both the precision and scalability required at that level.
As AI Glasses become part of everyday life, our ambition is clear:
To become the global leader in the manufacturing infrastructure that makes this technology possible.
