Optimized Micro-Pattern Design and Fabrication of a Light Guide Plate Using Micro-Injection Molding

This study examined the uniformity of illuminance field distributions of light guide plates (LGPs). First, the authors designed microstructural patterns on the surface of an LGP. Then, a mold of the LGP with the optimal microstructural design was fabricated by a photolithography method. Micro-injection molding (μIM) was used to manufacture the molded LGPs. μIM technology can simultaneously manufacture large-sized wedge-shaped LGPs and micro-scale microstructures. Finally, illuminance values of the field distributions of the LGPs with various microstructures were obtained through optical field measurements. This study compared the illuminance field distributions of LGPs with various designs and structures, which included LGPs without and those with microstructure on the primary design and the optimal design. The average illuminance of the LGP with microstructures and the optimal design was roughly 196.1 cd/m2. Its average illuminance was 1.3 times that of the LGP without microstructures. This study also discusses illuminance field distributions of LGPs with microstructures that were influenced by various μIM process parameters. The mold temperature was found to be the most important processing parameter affecting the illuminance field distribution of molded LGPs fabricated by μIM. The molded LGP with microstructures and the optimal design had better uniformity than that with microstructures and the primary design and that without microstructures. The uniformity of the LGP with microstructures and the optimal design was roughly 86.4%. Its uniformity was nearly 1.65 times that of the LGP without microstructures. The optimized design and fabrication of LGPs with microstructure exhibited good uniformity of illuminance field distributions.

Micro injection molding of individualised implants using 3D printed molds manufactured via digital light processing

Here, we demonstrate a manufacturing process for individualised, small-sized implant prototypes. Our process is promising for the manufacturing of drug-releasing (micro)implants to be implanted in the round window niche (RWN-I, solid body, free-form-shaped design, 1.1 x 2.7 x 3.1 mm) and for frontal neo-ostium implants (FO-I, tube-like design, length ~ 7 mm, Ø ~ 2-6 mm) for frontal sinus drainage. Implant prototypes are manufactured using micro injection molding (μIM). We use digital light processing (DLP) as a 3D printing technique for rapid tooling of accurate molds for the μIM process. A common acrylate-based photopolymer for stiff and high-detailed modelling but with low head deflection temperature of HDT = 60.5 °C is used for DLP 3D printing of the molds. The molds were 3D printed with a layer height of 50 μm in about 20 min (RWN-I) and 60 min (FO-I). For μIM investigations, we use liquid silicone rubber (LSR) as a biocompatible and medically relevant material. Micro injection molding of LSR was investigated using mold temperatures between Tmold = 110 °C (long tcuring ~ 2 h) up to Tmold = 160 °C (short tcuring ~ 5 min). As a result, small-sized, complex-shaped implant prototypes of LSR can be successfully manufactured via μIM using high Tmold = 160 °C and short curing time. DLP 3D printing material with relative low HDT = 60.5 °C was suitable for μIM. There is no significant wear of the molds, when used for a low number of μIM cycles (n ~ 8). Design of metal mold housing has to be suitable (perfect fit of mold, no cavities facing the molds surface for prevention of thermal expansion of mold into cavities).

Fabrication of Poly(Vinylidene Fluoride)/Graphene Nano-Composite Micro-Parts with Increased β-Phase and Enhanced Toughness via Micro-Injection Molding

Based on poly(vinylidene fluoride)/graphene (PVDF/GP) nano-composite powder, with high β-phase content (>90%), prepared on our self-designed pan-mill mechanochemical reactor, the micro-injection molding of PVDF/GP composite was successfully realized and micro-parts with good replication and dimensional stability were achieved. The filling behaviors and the structure evolution of the composite during the extremely narrow channel of the micro-injection molding were systematically studied. In contrast to conventional injection molding, the extremely high injection speed and small cavity of micro-injection molding produced a high shear force and cooling rate, leading to the obvious “skin-core” structure of the micro-parts and the orientation of both PVDF and GP in the shear layer, thus, endowing the micro-parts with a higher melting point and crystallinity and also inducing the transformation of more α-phase PVDF to β-phase. At the injection speed of 500 mm/s, the β-phase PVDF in the micro-part was 78%, almost two times of that in the macro-part, which was beneficial to improve the dielectric properties. The micro-part had the higher tensile strength (57.6 MPa) and elongation at break (53.6%) than those of the macro-part, due to its increased crystallinity and β-phase content.

Tuning Power Ultrasound for Enhanced Performance of Thermoplastic Micro-Injection Molding: Principles, Methods, and Performances

With the wide application of Micro-Electro-Mechanical Systems (MEMSs), especially the rapid development of wearable flexible electronics technology, the efficient production of micro-parts with thermoplastic polymers will be the core technology of the harvesting market. However, it is significantly restrained by the limitations of the traditional micro-injection-molding (MIM) process, such as replication fidelity, material utilization, and energy consumption. Currently, the increasing investigation has been focused on the ultrasonic-assisted micro-injection molding (UAMIM) and ultrasonic plasticization micro-injection molding (UPMIM), which has the advantages of new plasticization principle, high replication fidelity, and cost-effectiveness. The aim of this review is to present the latest research activities on the action mechanism of power ultrasound in various polymer micro-molding processes. At the beginning of this review, the physical changes, chemical changes, and morphological evolution mechanism of various thermoplastic polymers under different application modes of ultrasonic energy field are introduced. Subsequently, the process principles, characteristics, and latest developments of UAMIM and UPMIM are scientifically summarized. Particularly, some representative performance advantages of different polymers based on ultrasonic plasticization are further exemplified with a deeper understanding of polymer–MIM relationships. Finally, the challenges and opportunities of power ultrasound in MIM are prospected, such as the mechanism understanding and commercial application.

Experimental Investigation and Molecular Dynamics Simulation on the Anti-Adhesion Behavior of Alkanethiols on Nickel Insert in Micro Injection Molding

Due to the adhesion between the polymer melt and nickel (Ni) mold insert in the micro injection molding process, deformation defects frequently occur when the microstructures are demolded from the insert. In this study, self-assembled alkanethiols were applied to modify the surface of Ni mold insert to reduce its surface energy. Experimental trials were undertaken to explore the effect of alkanethiols coating on the replication quality. After that, molecular dynamics (MD) simulation was then used to investigate the adhesion behavior between the self-assembled coating and polypropylene (PP) by establishing three different types of alkanethiol material. The interaction energy, the potential energy change and radial distribution function were calculated to study the anti-adhesion mechanism. Experimental results show that all the three coatings can effectively decrease the adhesion and therefore promote the replication fidelity. It is demonstrated in MD simulation that the adhesion mainly comes from the van der Waals (vdW) force at the interface. The arrangement of sulfur atom on the Ni surface results in different absorbing behaviors. Compared with that of the PP–Ni interface, the interfacial energy and adhesion work after surface treatment is significantly reduced.

Design and Experimental Validation of a Process Chain for Thin Components Manufacturing by Micro Injection Molding Process

Micro applications, especially in biomedical and optical sectors, require the fabrication of thin polymeric parts which can be commonly realized by micro injection molding process. However, this process is characterized by a relevant constraint regarding the tooling. Indeed, the design and manufacturing of molds could be a very time-consuming step and so, a significant limitation for the rapid development of new products. Moreover, if the design displays challenging micro-features, their realization could involve the use of more than one mold for the fabrication of a single thin part. Therefore, a proper integration of different manufacturing micro technologies may represent an advantageous method to realise such polymeric thin micro features. In this work, a micro-manufacturing process chain including stereolithography, micro milling and micro injection molding is reported. The mold for the micro injection molding process was fabricated by means of stereolithography and micro milling, which allowed to produce low-cost reconfigurable modular mold, composed by an insert support and a removable insert. The assessment of the proposed process chain was carried out by evaluating the dimensions and the surface finishing and texturing of the milled mold cavities and molded components. Finally, a brief economic analysis compares three process chains for fabricating the micro mold showing that proposed one reduces manufacturing cost of almost 61% with the same production time.

Micro Injection Molding of Thin Cavities Using Stereolithography for Mold Fabrication

At the present time, there is a growing interest in additive manufacturing (AM) technologies and their integration into current process chains. In particular, the implementation of AM for tool production in micro injection molding (µ-IM), a well-established process, could introduce many advantages. First of all, AM could avoid the need for the time-consuming and expensive fabrication of molds for small series of customized products. In this work, the feasibility, quality, and reliability of an AM/µ-IM process chain were evaluated by designing and fabricating mold inserts for µ-IM by stereolithography (SLA) technology; the mold inserts were characterized and tested experimentally. The selected geometry is composed of four thin cavities: This particular feature represents an actual challenge for both the SLA and µ-IM perspective due to the large surface-to-volume ratio of the cavity. Two different materials were used for the mold fabrication, showing sharply different performance in terms of endurance limit and cavity degradation. The obtained results confirm that the µ-IM process, exploiting an SLA fabricated mold insert, is feasible but requires great accuracy in material choice, mold design, fabrication, and assembly.