Micro-Feature Replication via Polymer Molding at Ambient Pressure

2007 ◽  
Author(s):  
Varun Thakur ◽  
Peiman Mosaddegh ◽  
David C. Angstadt
Keyword(s):  
Amorphous Materials ◽  
Ambient Pressure ◽  
Applied Pressure ◽  
Crystalline Polymer ◽  
Lower Surface ◽  
Mold Temperature ◽  
Silicon Mold ◽  
Aspect Ratios ◽  
Molded Parts ◽  
Micro Features

The study focuses on the ability of a polymer to replicate micro-features when processed at an elevated mold temperature without externally applied pressure. Replication is performed using four different polymers—High Density Polyethylene (HDPE), Polypropylene (PP), Polystyrene (PS), and Poly (Methyl Methacrylate) (PMMA) on a silicon mold containing surface features as small as 500nm. Feature replication is assessed using scanning electron microscopy (SEM) and atomic force microscopy (AFM) to compare feature dimensions of the mold to those of the replicated parts. Shrinkage in dimensions is observed to be anisotropic in the molded parts and its extent of varies among the different polymers. Crystalline HDPE shows a higher degree of shrinkage relative to amorphous polymers such as PS and PMMA. These results verify the theoretical value of shrinkage calculated from the coefficient of volumetric shrinkage values and density. By increasing the mold temperature well above the melting point of the polymer, a depth ratio of 70–80% can be achieved in parts having aspect ratios of around 0.5. The result is comparable to the values achieved by similar studies. Varying aspect ratios are fully replicated by all four polymers at elevated mold temperature. This clearly shows that increasing mold temperature results in significant improvement in depth ratios for micro-featured parts. The amorphous materials provide better feature replication and lower surface roughness than the semi-crystalline polymer.

Effect of mold surface antistiction treatment on microinjection replication quality using Cr-N/Zr-DLC thin-layer coating

2012 ◽  
Vol 32 (6-7) ◽  
pp. 389-399 ◽  
Author(s):  
Ming-Shyan Huang ◽  
Yu-Sen Yang ◽  
Wen-Shin Hsu ◽  
Shih-Chih Nian
Keyword(s):  
Lower Surface ◽  
Mold Temperature ◽  
Mold Surface ◽  
Replication Rate ◽  
Dlc Coating ◽  
Control Factors ◽  
Unbalanced Magnetron Sputtering ◽  
Unbalanced Magnetron ◽  
Molded Parts ◽  
Replication Quality

Abstract Sticking in microinjection molds is a significant problem in controlling the qualities of molded parts such as replication rate and appearance. To resolve the problem, this study investigates the effect of chromium nitride (Cr-N) and diamond-like carbon that contains zirconium (Zr-DLC) layers deposited on mold inserts on the antisticking properties of molds. The injection-molded flat plate used is 0.4 mm thick and has 5, 10, and 20 μm high v-grooved microfeatures. To evaluate the importance of the major control factors in determining the microinjection molding quality and to obtain the optimal settings of those factors, the Taguchi method and analysis of variance were utilized. The sticking behaviors of the melt plastics on the cavities that were deposited Cr-N/Zr-DLC layers using an unbalanced magnetron sputtering process were studied with scanning electron microscopy. The experimental results indicate that an antistiction coating most strongly affects replication quality and is followed in that respect by the mold temperature and the barrel temperature. As the dimensions of the microfeatures decrease, the effect of the mold temperature on replication rate becomes more significant. In particular, a Zr-DLC coating on the mold surface yields a low coefficient of friction and a low resistance to the flow of polymer during cavity filling, improving the replication of the heights of the microfeatures. Nevertheless, a Cr-N coating provides better antisticking. This improvement follows from the lower stripping force, which results in the lower surface free energy on the Cr-N layers.

The Influence of Micro Scale Ratchet Depth on the Motion of Leidenfrost Drop

2015 ◽  
Author(s):  
Jeong Tae Ok ◽  
Sunggook Park
Keyword(s):  
Surface Temperature ◽  
Water Drop ◽  
Lower Surface ◽  
Driving Mechanism ◽  
Entire Surface ◽  
Depth Effect ◽  
Micro Scale ◽  
Temperature Range ◽  
Aspect Ratios ◽  
Surface Temperatures

The influence of ratchet depth on the motion of Leidenfrost water drop was investigated as a continuous effort to reveal the driving mechanism. Continuous directional rebounding behavior of the drop was observed only at below 200°C on both micro ratchets with two different depth-to-period aspect ratios (1:5 and 1:10) and sharp ridges. Overall, the shallow ratchets generated more efficient drop mobility in the entire surface temperature range of 193–299°C due to the increased area between the bottom of the drop and the ratchet surface, caused by the geometrical benefit. However, the depth effect was only critical at relatively lower surface temperatures.

Effect of Processing Conditions on the Shrinkage and Warpage of Glass Fiber Reinforced PP Using Microcellular Injection Molding

2012 ◽  
Vol 501 ◽  
pp. 294-299 ◽  
Author(s):  
Zhi Bian ◽  
Peng Cheng Xie ◽  
Yu Mei Ding ◽  
Wei Min Yang
Keyword(s):  
Injection Molding ◽  
Glass Fiber ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Process Conditions ◽  
Fiber Reinforced ◽  
Injection Speed ◽  
Glass Fiber Reinforced ◽  
Microcellular Injection Molding ◽  
Molded Parts

This study was aimed at understanding how the process conditions affected the dimensional stability of glass fiber reinforced PP by microcellular injection molding. A design of experiments (DOE) was performed and plane test specimens were produced for the shrinkage and warpage analysis. Injection molding trials were performed by systematically adjusting six process parameters (i.e., Injection speed, Injection pressure, Shot temperature, SCF level, Mold temperature, and Cooling time). By analyzing the statistically significant main and two-factor interaction effects, the results showed that the supercritical fluid (SCF) level and the injection speed affected the shrinkage and warpage of microcellular injection molded parts the most.

Direct Sinter Bonding of Metal Injection-Molded Parts to Solid Substrate Through Use of Deformable Surface Microfeatures

2013 ◽  
Vol 1 (1) ◽  
Author(s):  
Thomas Martens ◽  
M. Laine Mears
Keyword(s):  
Injection Molding ◽  
Solid Substrate ◽  
Metal Injection Molding ◽  
Full Density ◽  
Metal Powders ◽  
Molded Parts ◽  
Primary Obstacle ◽  
Injection Molded ◽  
Sinter Bonding ◽  
Micro Features

In the metal injection molding (MIM) process, fine metal powders are mixed with a binder and injected into molds, similar to plastic injection molding. After molding, the binder is removed from the part, and the compact is sintered to almost full density. Though able to create high-density parts of excellent dimensional control and surface finish, the MIM process is restricted in the size of part that can be produced, due to gravitational deformation during high-temperature sintering and maximum thickness requirements to remove the binding agents in the green state. Larger parts could be made by bonding the green parts to a substrate during sintering; however, a primary obstacle to this approach lies in the sinter shrinkage of the MIM part, which can be up to 20%, meaning that the MIM part shrinks during sintering, while the conventional substrate maintains its dimensions. This behavior would typically inhibit bonding and/or cause cracking and deformation of the MIM part. In this work, we present a structure of micro features molded onto the surface of the MIM part, which bonds, deforms, and allows for shrinkage while bonding to the substrate. The micro features tolerate plastic deformation to permit the shrinkage without causing cracks after the initial bonds are established. In a first series of tests, bond strengths of up to 80% of that of resistance welds have been achieved. This paper describes how the authors developed their proposed method of sinter bonding and how they accomplished effective sinter bonds between MIM parts and solid substrates.

Constant-Temperature Embossing of Amorphous Poly(Ethylene Terephthalate) Films

2007 ◽  
Author(s):  
Donggang Yao ◽  
Pratapkumar Nagarajan ◽  
K. R. T. Ramasubramani
Keyword(s):  
Thermal Cycling ◽  
Amorphous Phase ◽  
Constant Temperature ◽  
Ethylene Terephthalate ◽  
Mold Temperature ◽  
Cycle Times ◽  
Poly Ethylene Terephthalate ◽  
Micro Features ◽  
Poly Ethylene ◽  
Pet Film

In the standard hot embossing process for thermoplastic polymers, thermal cycling is needed in order to soften and subsequently cool and solidify the polymer. This thermal cycling, however, not only results in long cycle times but also deteriorates the quality of embossed features. A new embossing method based on slowly crystallizing polymers was investigated to eliminate thermal cycling. Poly(ethylene terephthalate) was used as a model system for demonstration. Due to its slow crystallization, amorphous PET film can be made by casting a PET melt onto a chill roll. The amorphous PET film was embossed at a constant temperature of 180°C for a period of time comparable to or longer than PET’s half-time of crystallization. During constant-temperature embossing, the film first liquefies, caused by rubber softening of the amorphous phase, and then solidifies, resulting from the crystallization of the amorphous phase. Since the embossed film is hardened under the constant mold temperature, no cooling is needed. Selected micro features, including circular microchannels and high aspect ratio rectangular microchannels, were successfully embossed using a total cycle time about 40 s.

scholarly journals Characterization of Stereolithography Printed Soft Tooling for Micro Injection Molding

Micromachines ◽  
2020 ◽  
Vol 11 (9) ◽  
pp. 819 ◽  
Author(s):  
Daniel Dempsey ◽  
Sean McDonald ◽  
Davide Masato ◽  
Carol Barry
Keyword(s):  
Aspect Ratio ◽  
Injection Molding ◽  
Raw Materials ◽  
Tool Material ◽  
Mold Temperature ◽  
Micro Injection Molding ◽  
Digital Light Processing ◽  
Electron Microscopies ◽  
Aspect Ratios ◽  
The Impact

The use of microfeature-enabled devices, such as microfluidic platforms and anti-fouling surfaces, has grown in both potential and application in recent years. Injection molding is an attractive method of manufacturing these devices due to its excellent process throughput and commodity-priced raw materials. Still, the manufacture of micro-structured tooling remains a slow and expensive endeavor. This work investigated the feasibility of utilizing additive manufacturing, specifically a Digital Light Processing (DLP)-based inverted stereolithography process, to produce thermoset polymer-based tooling for micro injection molding. Inserts were created with an array of 100-μm wide micro-features, having different heights and thus aspect ratios. These inserts were molded with high flow polypropylene to investigate print process resolution capabilities, channel replication abilities, and insert wear and longevity. Samples were characterized using contact profilometry as well as optical and scanning electron microscopies. Overall, the inserts exhibited a maximum lifetime of 78 molding cycles and failed by cracking of the entire insert. Damage was observed for the higher aspect ratio features but not the lower aspect ratio features. The effect of the tool material on mold temperature distribution was modeled to analyze the impact of processing and mold design.

scholarly journals Evidence for a pressure-induced antiferromagnetic quantum critical point in intermediate-valence UTe2

2020 ◽  
Vol 6 (42) ◽  
pp. eabc8709 ◽  
Author(s):  
S. M. Thomas ◽  
F. B. Santos ◽  
M. H. Christensen ◽  
T. Asaba ◽  
F. Ronning ◽  
...  
Keyword(s):  
Ambient Pressure ◽  
Applied Pressure ◽  
Quantum Critical Point ◽  
Antiferromagnetic Order ◽  
Intermediate Valence ◽  
Ac Calorimetry ◽  
Unconventional Superconductor ◽  
Spin Triplet ◽  
Magnetic States ◽  
Low Pressures

UTe2 is a recently discovered unconventional superconductor that has attracted much interest because of its potentially spin-triplet topological superconductivity. Our ac calorimetry, electrical resistivity, and x-ray absorption study of UTe2 under applied pressure reveals key insights on the superconducting and magnetic states surrounding pressure-induced quantum criticality at Pc1 = 1.3 GPa. First, our specific heat data at low pressures, combined with a phenomenological model, show that pressure alters the balance between two closely competing superconducting orders. Second, near 1.5 GPa, we detect two bulk transitions that trigger changes in the resistivity, which are consistent with antiferromagnetic order, rather than ferromagnetism. Third, the emergence of magnetism is accompanied by an increase in valence toward a U4+ (5f2) state, which indicates that UTe2 exhibits intermediate valence at ambient pressure. Our results suggest that antiferromagnetic fluctuations may play a more substantial role on the superconducting state of UTe2 than previously thought.

Surface Replication and Structural Development in Micromolding for Micro/Nanocomposites

2007 ◽  
Author(s):  
H. Ito ◽  
K. Kazama ◽  
T. Kikutani
Keyword(s):  
Laser Scanning ◽  
Hexagonal Boron Nitride ◽  
Laser Scanning Microscopy ◽  
Surface Pattern ◽  
Confocal Laser ◽  
Order Structure ◽  
Structural Development ◽  
Molded Parts ◽  
Surface Patterns ◽  
Micro Features

Micromolding with micro-scale surface features of hexagonal boron nitride (h-BN) / polypropylene (PP) composites with different h-BN component was performed to improve molded parts’ heat diffusivity and processability. Effects of h-BN content and process parameters on processability, higher-order structure, and microscale surface patterns of molded parts were analyzed using SEM, WAXD, SPM, and confocal laser scanning microscopy. The replication ratio of the microscale surface pattern and flow length of composite molded parts was improved by compounding the h-BN filler. The replication ratio of the microscale surface pattern near the flow end became greater than 1.0 because of deformation of surface patterns during de-molding. The replication ratio and shape of surface patterns of molded parts were improved with the increase of the h-BN component. The h-BN platelet oriented inside surface micro-features; skin-shear-core structures were well observed in the molded parts.

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