Microinjection moulding has been developed to fulfil the needs of mass production of micro components in different fields. A challenge of this technology lies in the downscaling of micro components, which leads to faster solidification of the polymeric material and a narrower process window. Moreover, the small cavity dimensions represent a limit for process monitoring due to the inability to install in-cavity sensors. Therefore, new solutions must be found. In this study, the downscaling effect was investigated by means of three spiral geometries with different cross sections, considering the achievable flow length as a response variable. Process indicators, called “process fingerprints”, were defined to monitor the process in-line. In the first stage, a relationship between the achievable flow length and the process parameters, as well as between the process fingerprints and the process parameters, was established. Subsequently, a correlation analysis was carried out to find the process indicators that are mostly related to the achievable flow length.
Precision replication of microlens arrays using variotherm-assisted microinjection moulding
