Surface Microstructure Replication in Injection Moulding

Hans Nørgaard Hansen, Uffe Rolf Arlø

    Research output: Chapter in Book/Report/Conference proceedingArticle in proceedingsResearchpeer-review


    In recent years polymer components with surface microstructures have been in rising demand for applications such as lab-on-a-chip and optical components. Injection moulding has proven to be a feasible and efficient way to manufacture such components. In injection moulding the mould surface topography is transcribed onto the plastic part through complex mechanisms. This replication however, is not perfect, and the replication quality depends on the plastic material properties, the topography itself, and the process conditions. This paper describes and discusses an investigation of injection moulding of surface microstructures. Emphasis is put on the ability to replicate surface microstructures under normal injection moulding conditions, notably with low cost materials at low mould temperatures. The replication of surface microstructures in injection moulding has been explored for Polypropylene at low mould temperatures. The process conditions were varied over the recommended process window for the material. The geometry of the obtained structures was analyzed. Evidence suggests that step height replication quality depends linearly on structure width in a certain range. Further it was found that in this range, the replication quality depends strongly on process conditions. It was concluded that the achieved step height varies linearly with the mould groove width.
    Original languageEnglish
    Title of host publicationProc. of the 1st 4M Int. Conf. on Multi Material Micro Manufacture
    EditorsW. Menz and S. Dimov
    Publication date2005
    Publication statusPublished - 2005
    Event1st International Conference on Multi-Material Micro Manufacture (4M2005) - Karlshrue, Germany
    Duration: 29 Jun 20051 Jul 2005
    Conference number: 1


    Conference1st International Conference on Multi-Material Micro Manufacture (4M2005)


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