Journal
CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY
Volume 23, Issue -, Pages 20-38Publisher
ELSEVIER SCIENCE BV
DOI: 10.1016/j.cirpj.2018.10.002
Keywords
Warm/cold circuit temperatures; Replication integrity; Vacuum venting; Process characterisation
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Funding
- China Scholarship Council, Science Foundation Ireland (SFI) [15/RP/B3208, 14/IFB/2719]
- National Science Foundation of China [61675149, 51320105009, 61635008]
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Micro features on surfaces are critical for the functionality of a product, such as micro channels for a microfluidic chip and micro lens arrays for an artificial compound eye lens. In the present work, we design a series of microfluidic and microstructured surface patterns to evaluate the influence of variotherm and vacuum venting on replication integrity of micro features. By using a process monitoring system, including machine process and cavity pressure/temperature measurements, the influence of warm and cold circuit settings, and vacuum venting are characterised in terms of injection pressure, cavity pressure and mould-polymer interface temperature. These are then correlated with the replication integrity of micro features by assessing feature replication height, cross-section area and surface morphology. The performance of anti-stick coatings on a micro mould tool insert was also characterised in terms of moulding cycles. After a series experiments and optimisation, we have significantly enhanced feature replication with 100% replication of proposed features without either significant distortion or tearing, which cannot easily be achieved using conventional injection moulding. Additionally, we have successfully moulded features having good integrity and a maximum aspect ratio of up to 10 at a width of less than 81 mu m over areas as large as 5.25 mm(2). (C) 2018 CIRP.
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