Towards the analytic characterization of micro and nano surface features using the Biharmonic equation

YesThe prevalence of micromoulded components has steadily increased over recent years. The production of such components is extremely sensitive to a number of variables that may potentially lead to significant changes in the surface geometry, often regarded as a crucial determinant of the product¿s functionality and quality. So far, traditional large-scale quality assessment techniques have been used in micromoulding. However, these techniques are not entirely suitable for small scales . Techniques such as Atomic Force Mi- croscopy (AFM) or White Light Interferometry (WLI) have been used for obtaining full three-dimensional profiles of micromoulded components, pro- ducing large data sets that are very difficult to manage. This work presents a method of characterizing surface features of micro and nano scale based on the use of the Biharmonic equation as means of describing surface profiles whilst guaranteeing tangential (C1) continuity. Thus, the problem of rep- resenting surface features of micromoulded components from massive point clouds is transformed into a boundary-value problem, reducing the amount of data required to describe any given surface feature.The boundary conditions needed for finding a particular solution to the Biharmonic equation are extracted from the data set and the coefficients associated with a suitable analytic solution are used to describe key design parameters or geometric properties of a surface feature. Moreover, the expressions found for describ- ing key design parameters in terms of the analytic solution to the Biharmonic equation may lead to a more suitable quality assessment technique for mi- cromoulding than the criteria currently used. In summary this technique provides a means for compressing point clouds representing surface features whilst providing an analytic description of such features. The work is applicable to many other instances where surface topography is in need of efficient representation

Characterisation of demoulding parameters in micro-injection moulding

YesCondition monitoring of micro injection moulding is an effective way of understanding the processing effects of variable parameter settings. This paper reports an experimental study that investigates the characteristics of the demoulding behaviour in micro injection moulding (A mu-IM) with a focus on the process factors that affect parts' quality. Using a Cyclic Olefin Copolyme (COC) microfluidics demonstrator, the demoulding performance was studied as a function of four process parameters (melt temperature, mould temperature, holding pressure and injection speed), employing the design of experiment approach. The results provide empirical evidences on the effect that processing parameters have on demoulding conditions in A mu-IM, and identifies combinations of parameters that can be used to achieve the optimal processing conditions in regards to demoulding behaviour of micro parts. It was concluded that there was a direct correlation between the applied pressure during part filling, holding phases and the demoulding characteristic factors of the A mu-IM cycle such as ejection force, integral and time

Dissolving and Swelling Hydrogel-Based Microneedles: An Overview of Their Materials, Fabrication, Characterization Methods, and Challenges

YesPolymeric hydrogels are a complex class of materials with one common feature—the ability to form three-dimensional networks capable of imbibing large amounts of water or biological fluids without being dissolved, acting as self-sustained containers for various purposes, including pharmaceutical and biomedical applications. Transdermal pharmaceutical microneedles are a pain-free drug delivery system that continues on the path to widespread adoption—regulatory guidelines are on the horizon, and investments in the field continue to grow annually. Recently, hydrogels have generated interest in the field of transdermal microneedles due to their tunable properties, allowing them to be exploited as delivery systems and extraction tools. As hydrogel microneedles are a new emerging technology, their fabrication faces various challenges that must be resolved for them to redeem themselves as a viable pharmaceutical option. This article discusses hydrogel microneedles from a material perspective, regardless of their mechanism of action. It cites the recent advances in their formulation, presents relevant fabrication and characterization methods, and discusses manufacturing and regulatory challenges facing these emerging technologies before their approval

Thermal contact resistance in micromoulding.

yesThis work outlines a novel approach for determining thermal contact resistance (TCR) in micromoulding. The proposed technique aims to produce TCR predictions with known confidence values and combines experimental evidence (temperature fields and contact angle measurements) with various mathematical modelling procedures (parametric representation of surfaces, finite element analysis and stochastic processes). Here, emphasis is made on the mathematical aspects of the project. In particular, we focus on the description of the parametric surface representation technique based on the use of partial differential equations, known as the PDE method, which will be responsible for characterizing and compressing micro features in either moulds or surface tools.EPSR

A new process chain for producing bulk metallic glass replication masters with micro- and nano-scale features

YesA novel process chain for serial production of polymer-based devices incorporating both micro- and nano-scale features is proposed. The process chain is enabled by the use of Zr-based bulk metallic glasses (BMG) to achieve the necessary level of compatibility and complementarity between its component technologies. It integrates two different technologies, namely laser ablation and focused ion beam (FIB) milling for micro-structuring and sub-micron patterning, respectively, thus to fabricate inserts incorporating different length scale functional features. Two alternative laser sources, namely nano-second (NS) and pico-second (PS) lasers, were considered as potential candidates for the first step in this master-making process chain. The capabilities of the component technologies together with some issues associated with their integration were studied. To validate the replication performance of the produced masters, a Zr-based BMG insert was used to produce a small batch of micro-fluidic devices by micro-injection moulding. Furthermore, an experimental study was also carried out to determine whether it would be possible by NS laser ablation to structure the Zr-based BMG workpieces with a high surface integrity whilst retaining the BMG's non-crystalline morphology. Collectively, it was demonstrated that the proposed process chain could be a viable fabrication route for mass production of polymer devices incorporating different length scale features

Mechanical durability of hydrophobic surfaces fabricated by injection moulding of laser-induced textures

YesThe paper reports an investigation on the mechanical durability of textured thermoplastic surfaces together with their respective wetting properties. A range of laser-induced topographies with different aspect ratios from micro to nanoscale were fabricated on tool steel inserts using an ultrashort pulsed near infrared laser. Then, through micro-injection moulding the topographies were replicated onto polypropylene surfaces and their durability was studied systematically. In particular, the evolution of topographies on textured thermoplastic surfaces together with their wetting properties were investigated after undergoing a controlled mechanical abrasion, i.e. reciprocating dry and wet cleaning cycles. The obtained empirical data was used both to study the effects of cleaning cycles and also to identify cleaning procedures with a minimal impact on textured thermoplastic surfaces and their respective wetting properties. In addition, the use of 3D areal parameters that are standardised and could be obtained readily with any state-of-the-art surface characterisation system are discussed for monitoring the surfaces' functional response.European Commission H2020 ITN programme “European ESRs Network on Short Pulsed Laser Micro/Nanostructuring of Surfaces for Improved Functional Applications” (Laser4Fun) under the Marie Skłodowska-Curie grant agreement No. 675063 (www.laser4fun.eu) and the UKIERI DST programme “Surface functionalisation for food, packaging, and healthcare applications”. In addition, the work was supported by three other H2020 programmes, i.e. the projects on “Modular laser based additive manufacturing platform for large scale industrial applications” (MAESTRO), “High-Impact Injection Moulding Platform for mass-production of 3D and/or large micro-structured surfaces with Antimicrobial, Self-cleaning, Anti-scratch, Anti-squeak and Aesthetic functionalities” (HIMALAIA) and “Process Fingerprint for Zero-defect Net-shape Micromanufacturing” (MICROMAN)

Investigation of Plasma Treatment on Micro-Injection Moulded Microneedle for Drug Delivery

YesPlasma technology has been widely used to increase the surface energy of the polymer surfaces for many industrial applications; in particular to increase in wettability. The present work was carried out to investigate how surface modification using plasma treatment modifies the surface energy of micro-injection moulded microneedles and its influence on drug delivery. Microneedles of polyether ether ketone and polycarbonate and have been manufactured using micro-injection moulding and samples from each production batch have been subsequently subjected to a range of plasma treatment. These samples were coated with bovine serum albumin to study the protein adsorption on these treated polymer surfaces. Sample surfaces structures, before and after treatment, were studied using atomic force microscope and surface energies have been obtained using contact angle measurement and calculated using the Owens-Wendt theory. Adsorption performance of bovine serum albumin and release kinetics for each sample set was assessed using a Franz diffusion cell. Results indicate that plasma treatment significantly increases the surface energy and roughness of the microneedles resulting in better adsorption and release of BSA

Flow-induced crystallization of long chain aliphatic polyamides under a complex flow field: Inverted anisotropic structure and formation mechanism

YesThe present work deals with the flow-induced multiple orientations and crystallization structure of polymer melts under a complex flow field. This complex flow field is characteristic of the consistent coupling of extensional “pulse” and closely followed shear flow in a narrow channel. Utilizing an ingenious combination of an advanced micro-injection device and long chain aliphatic polyamides (LCPA), the flow-induced crystallization morphology was well preserved for ex-situ synchrotron micro-focused wide angle X-ray scattering (μWAXS) as well as small angle X-ray scattering (SAXS). An inverted anisotropic crystallization structure was observed in two directions: perpendicular and parallel to the flow direction (FD). The novel anisotropic morphology implies the occurrence of wall slip and “global” fountain flow under the complex flow field. The mechanism of structure formation is elucidated in detail. The experimental results clearly indicate that the effect of extensional pulse on the polymer melt is restrained and further diminished due to either the transverse tumble of fountain flow or the rapid retraction of stretched high molecular weight tails. However, the residual shish-kebab structures in the core layer of the far-end of channel suggest that the effect of extensional pulse should be considered in the small-scaled geometries or under the high strain rate condition

Lotus-leaf inspired surfaces: hydrophobicity evolution of replicas due to mechanical cleaning and mold wear

YesInspired from the low wetting properties of Lotus leaves, the fabrication of dual micro/nano-scale topographies is of interest to many applications. In this research, superhydrophobic surfaces are fabricated by a process chain combining ultrashort pulsed laser texturing of steel inserts and injection moulding to produce textured polypropylene parts. This manufacturing route is very promising and could be economically viable for mass production of polymeric parts with superhydrophobic properties. However, surface damages, such as wear and abrasion phenomena, can be detrimental to the attractive wetting properties of replicated textured surfaces. Therefore, the final product lifespan is investigated by employing mechanical cleaning of textured polypropylene surfaces with multipurpose cloths following the ASTM D3450 standard. Secondly, the surface damage of replication masters after 350 injection moulding cycles with glass-fiber reinforced polypropylene, especially to intensify mould wear, was investigated. In both cases, the degradation of the dual-scale surface textures had a clear impact on surface topography of the replicas and thus on their wetting properties, too.Europe Union H2020 research and innovation programme

Microneedle assisted transdermal delivery of zolmitriptan: effect of microneedle geometry, in vitro permeation experiments, scaling analyses and numerical simulations

Objective: The present study was aimed to investigate the effect of salient microneedle (MN) geometry parameters like length, density, shape and type on transdermal permeation enhancement of Zolmitriptan (ZMT). Methods: Two types of MN devices viz. AdminPatch® arrays (ADM) (0.6, 0.9, 1.2 and 1.5mm lengths) and laboratory fabricated polymeric MNs (PM) of 0.6mm length were employed. In the case of PMs, arrays were applied thrice at different places within a 1.77cm2 skin area (PM-3) to maintain the MN density closer to 0.6mm ADM. Scaling analyses was done using dimensionless parameters like concentration of ZMT (Ct/Cs), thickness (h/L) and surface area of the skin (Sa/L2). Results: Micro-injection moulding technique was employed to fabricate PM. Histological studies revealed that the PM, owing to their geometry/design, formed wider and deeper microconduits when compared to ADM of similar length. Approximately 3.17 and 3.65 fold increase in ZMT flux values were observed with 1.5mm ADM and PM-3 applications when compared to the passive studies. Good correlations were observed between different dimensionless parameters with scaling analyses. Numerical simulations, using MATLAB and COMSOL software, based on experimental data and histological images provided information regarding the ZMT skin distribution after MN application. Discussion: Both from experimental studies and simulations, it was inferred that PM were more effective in enhancing the transdermal delivery of ZMT when compared to ADM. Conclusion: The study suggests that MN application enhances the ZMT transdermal permeation and the geometrical parameters of MNs play an important role in the degree of such enhancement