Investigation of product and process fingerprints for fast quality assurance in injection molding of micro-structured components

Injection molding is increasingly gaining favor in the manufacturing of polymer components since it can ensure a cost-efficient production with short cycle times. To ensure the quality of the finished parts and the stability of the process, it is essential to perform frequent metrological inspections. In contrast to the short cycle time of injection molding itself, a metrological quality control can require a significant amount of time and the late detection of a problem may then result in increased wastage. This paper presents an alternative approach to process monitoring and the quality control of injection molded parts with the concept of “Product and Process Fingerprints„ that use direct and indirect quality indicators extracted from part quality data in-mold and machine processed data. The proposed approach is based on the concept of product and process fingerprints in the form of calculated indices that are correlated to the quality of the molded parts. A statistically designed set of experiments was undertaken to map the experimental space and quantify the replication of micro-features depending on their position and on combinations of processing parameters with their main effects to discover to what extent the effects of process variation were dependent on feature shape, size, and position. The results show that a number of product and process fingerprints correlate well with the quality of the micro features of the manufactured part depending on their geometry and location and can be used as indirect indicators of part quality. The concept can, thus, support the creation of a rapid quality monitoring system that has the potential to decrease the use of off-line, time-consuming, and detailed metrology for part approval and can thus act as an early warning system during manufacturing

Surface-patterned micromechanical elements by polymer injection molding with hybrid molds

Hybrid molds enable the fabrication of polymeric parts with features of different length scales by injection molding. The resulting polymer microelements combine optical or biological functionalities with designed mechanical properties. Two applications are chosen for illustration of this concept: As a first example, microelements for optical communication via fiber-to-fiber coupling are manufactured by combining two molds to a small mold insert. Both molds are fabricated using lithography and electroplating. As a second example, microcantilevers (μCs) for chemical sensing are surface patterned using a modular mold composed of a laser-machined cavity defining the geometry of the μCs, and an opposite flat tool side which is covered by a patterned polymer foil. Injection molding results in an array of 35 μm-thick μCs with microscale surface topographies. In both cases, when the mold is assembled and closed, reliefs are transferred onto one surface of the molded element whose outlines are defined by the micromold cavity. The main advantage of these hybrid methods lies in the simple integration of optical surface structures and gratings onto the surface of microcomponents with different sizes and orientations. This allows for independent development of functional properties and combinations thereof

Nanoimprint lithography process chains for the fabrication of micro- and nanodevices

The nanoimprint lithography (NIL) process with its key elements molding and thin film pattern transfer refers to the established process chain of resist-based patterning of hard substrates. Typical processes for mass fabrication are either wafer-scale imprint or continuous roll-to-roll processes. In contrast to this, similar process chains were established for polymeric microelements fabricated by injection molding, particularly when surface topographies need to be integrated into monolithic polymer elements. NIL needs to be embedded into the frame- work of general replication technologies, with sizes ranging from nanoscopic details to macroscopic entities. This contribution presents elements of a generalized replication process chain involving NIL and demonstrates its wide application by presenting nontypical NIL products, such as an injection-molded microcantilever. Additionally, a hybrid approach combining NIL and injection molding in a single tool is presented. Its aim is to introduce a toolbox approach for nanoreplication into NIL-based processing and to facilitate the choice of suitable processes for micro- and nanodevices. By proposing a standardized process flow as described in the NaPANIL library of processes, the use of establish process sequences for new applications is facilitated

Nanometer-size anisotropy of injection-molded polymer micro-cantilever arrays

Understanding and controlling the structural anisotropies of injection-molded polymers is vital for designing products such as cantilever-based sensors. Such micro-cantilevers are considered as cost-effective alternatives to single-crystalline silicon-based sensors. In order to achieve similar sensing characteristics,structure and morphology have to be controlled by means of processing parameters including mold temperature and injection speed. Synchrotron radiation-based scanning small- (SAXS) and wide-angle x-ray scattering techniques were used to quantify crystallinity and anisotropy in polymer micro-cantilevers with micrometer resolution in real space. SAXS measurements confirmed the lamellar nature of the injection-molded semi-crystalline micro-cantilevers. The homogenous cantilever material exhibits a lamellar periodicity increasing with mold temperature but not with injection speed. We demonstrate that micro-cantilevers made of semi-crystalline polymers such as polyvinylidenefluoride, polyoxymethylene, and polypropylene show the expected strong degree of anisotropy along the injection direction

Extension and validation of a revised Cassie-Baxter model for tailor-made surface topography design and controlled wettability

Predicting wettability accurately across various materials, surface topographies and wetting liquids is undeniably of paramount importance as it sets the foundations for technological developments related to improved life quality, energy saving and economization of resources, thereby reducing the environmental impact for recycling and reuse. In this work, we extend and validate our recently published wetting model, constituting a refinement of the original Cassie-Baxter model after consideration of realistic curved liquid-air interfaces. Our model enabled more meaningful contact angle predictions, while it captured the experimentally observed trends between contact angle and surface roughness. Here, the formalism of our wetting model is further extended to 3D surface topographies, whereas the validity of our model, in its entirety, is evaluated. To this end, a total of thirty-two experimentally engineered surfaces of various materials exhibiting single- and multilevel hierarchical topographies of increasing complexity were utilized. Our model predictions were consistently in remarkable agreement with experimental data (deviations of 3%–6%) and, in most cases, within statistical inaccuracies of the experimental measurements. Direct comparison between experiments and modeling results corroborated that surface topographies featuring re-entrant geometries promoted enhanced liquid-repellency, whereas hierarchical multilevel surface topographies enabled even more pronounced nonwetting behaviors. For the sinusoidal topography, consideration of a second superimposing topography level almost doubled the observed water contact angles, whereas addition of a third level brought about an extra 12.5% increase in water contact angle

Advances in precision microfabrication through digital light processing: system development, material and applications

Digital Light Processing (DLP) is an advanced additive manufacturing technology which has garnered substantial recognition and has been extensively applications in various fields. This review focuses on the precision microfabrication process of DLP, providing an overview of the DLP 3D printing system, including the digital light engine, project lenses, motorised stage and resin vat for micro-structure fabrication. Additionally, this review paper comprehensively analyses commercially available DLP printers, covering resolution, cost and a detailed discussion on the importance of photopolymer resins, emphasising the monomer, photo-initiator, photo-absorber, etc. Based on the photopolymerisation theory, the DLP high-precision printing process is analysed, which is critical for producing complex microstructures. It also briefly discusses the application of DLP microfabrication including microfluidic chip printing. Finally, this paper summarises the advanced trends and challenges of DLP printing in high-precision, large-area, multi-material and high-speed printing; and it provides an in-depth understanding of DLP technology, highlighting its potential for various applications and addressing challenges that need to be overcome in future research

Surface wettability and tribological performance of Ni-based nanocomposite moulds against polymer materials

In the mass-production of microfluidic devices through micro hot embossing/injection moulding, the longevity of mould inserts is influenced by elevated adhesion and friction between the polymer and the mould. Thus, accurate prediction of mould lifespan requires a comprehensive understanding of surface wettability and tribological performance during polymer contact. The current study addresses this gap by characterizing fabricated micro-structured Ni, Ni-WS2, and Ni-PTFE nanocomposite moulds (surface morphologies, crystal structures and microhardness) to investigate inherent lubrication mechanisms. Surface wettability of mould material was systematically studied by measuring the contact angles with eight different polymer melts. Pin-on-disk tests with polymer pins made of cyclic olefin copolymer (COC 8007), polypropylene (PP), and poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) were conducted to elucidate the wear resistance of the nanocomposite moulds. Pressure-dependent friction coefficient and wear resistance were further explored under increasing external loads, simulating the actual moulding processes where contact pressure may vary considerably depending on the part shape. Results indicate that Ni-WS2 exhibits the highest microhardness (532 Hv), followed by Ni-PTFE (465 Hv) and Ni (198 Hv). Notably, Ni-PTFE demonstrates exceptional hydrophobicity against all polymer melts, signifying low surface energy during polymer contact. Moreover, both nanocomposite moulds exhibit reduced friction coefficients and enhanced wear resistance across various polymers. Counterintuitively, despite its lower hardness, the Ni-PTFE mould displays superior wear resistance against the COC pin under higher loads, while the Ni-WS2 mould experiences severe adhesive wear, as observed from wear morphology and profile analysis. This finding establishes the Ni-PTFE as a promising alternative as a mould insert material for precision manufacturing.</p

Enhanced thermal stability of a polymer solar cell blend induced by electron beam irradiation in the transmission electron microscope

We show by in situ microscopy that the effects of electron beam irradiation during transmission electron microscopy can be used to lock microstructural features and enhance the structural thermal stability of a nanostructured polymer:fullerene blend. Polymer:fullerene bulk-heterojunction thin films show great promise for use as active layers in organic solar cells but their low thermal stability is a hindrance. Lack of thermal stability complicates manufacturing and influences the lifetime of devices. To investigate how electron irradiation affects the thermal stability of polymer:fullerene films, a model bulk-heterojunction film based on a thiophene-quinoxaline copolymer and a fullerene derivative was heat-treated in-situ in a transmission electron microscope. In areas of the film that exposed to the electron beam the nanostructure of the film remained stable, while the nanostructure in areas not exposed to the electron beam underwent large phase separation and nucleation of fullerene crystals. UV–vis spectroscopy shows that the polymer:fullerene films are stable for electron doses up to 2000 kGy

Enhanced thermal stability of a polymer solar cell blend induced by electron beam irradiation in the transmission electron microscope

We show by in situ microscopy that the effects of electron beam irradiation during transmission electron microscopy can be used to lock microstructural features and enhance the structural thermal stability of a nanostructured polymer:fullerene blend. Polymer:fullerene bulk-heterojunction thin films show great promise for use as active layers in organic solar cells but their low thermal stability is a hindrance. Lack of thermal stability complicates manufacturing and influences the lifetime of devices. To investigate how electron irradiation affects the thermal stability of polymer:fullerene films, a model bulk-heterojunction film based on a thiophene-quinoxaline copolymer and a fullerene derivative was heat-treated in-situ in a transmission electron microscope. In areas of the film that exposed to the electron beam the nanostructure of the film remained stable, while the nanostructure in areas not exposed to the electron beam underwent large phase separation and nucleation of fullerene crystals. UV–vis spectroscopy shows that the polymer:fullerene films are stable for electron doses up to 2000 kGy