Key aspects of the technology and challenges associated with the micromoulding process are discussed. The apparent shear and extensional viscosity behaviour of a polyacetal at high wall shear rates have been measured using inline capillary rheometry on a commercial micromoulding machine and a larger servoelectric injection moulding machine; the polymer behaved predictably at shear rates in excess of 106 s -1. Initial moulding trials indicated that a stepped plaque and 0·25 mm thick rectangular plaque mouldings lled in a satisfactory manner, but a thicker plaque cavity exhibited a jetting ow into the cavity. A data capture system capable of measuring multiple process dynamics at high sampling rates (up to 50 kHz per channel) allowed detailed process measurements taken during moulding of the stepped plaque moulding. Atomic force microscopy of the moulded products showed diVerent surface nishes on each step of the stepped plaque moulding. Topography scans of the 0·25 mm thick rectangular plaque moulding showed that mould surface features with length scales of the order of a few micrometres were well replicated on the moulded product and the quality of the surface nish is dependent on the melt pressure during moulding.PRC/2020

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ABSTRACT:The rheology of a range of polymer melts has been measured at strain rates above those attained during conventional rheometry using an instrumented injection molding machine. Deviations from shear thinning behavior were observed at high rates, and previously unreported shear thickening behavior occurred for some of the polymers examined. Measured pressure and volumetric throughputs were used to calculate shear and extensional viscosity at wall shear strain rates up to 10 7 s À1 . Parallel plate rheometry and twin bore capillary rheometry were used to provide comparative rheological data at low and medium shear strain rates, respectively. Commercial grades of polyethylene, polypropylene, polystyrene, and PMMA were studied. Measured shear viscosity was found to follow Newtonian behavior at low rates and shear thinning power law behavior at intermediate strain rates. At shear strain rates approaching or above 10 6 s À1 , shear viscosity reached a rate-independent plateau, and in some cases shear thickened with further increase in strain rate. A relationship between the measured high strain rate rheological behavior and molecular structure was noted, with polymers containing larger side groups reaching the rate-independent plateau at lower strain rates than those with simpler structures.

Plasma 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.

CitationRomano J-M, Gülçür M, Garcia-Giron A et al (2019) Mechanical durability of hydrophobic surfaces fabricated by injection moulding of laser-induced textures. Applied Surface Science. 476: 850-860. Rights ABSTRACT.The 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.