A Review of Advanced Roll-to-Roll Manufacturing: System Modeling and Control

Abstract Roll-to-roll (R2R) manufacturing is a highly efficient industrial method for continuously processing flexible webs through a series of rollers. With advancements in technology, R2R manufacturing has emerged as one of the most economical production methods for advanced products, such as flexible electronics, renewable energy devices, and 2D materials. However, the development of cost-effective and efficient manufacturing processes for these products presents new challenges, including higher precision requirements, the need for improved in-line quality control, and the integration of material processing dynamics into the traditional web handling system. This paper reviews the state of the art in advanced R2R manufacturing, focusing on modeling and control, and highlights research areas that need further development.