Precise tooling is vital for defect-free production of micro injection moulded (μ-IM) or hot-embossed products. The demoulding stage of such moulding and forming processes poses a serious challenge to the integrity of thin miniature features because of friction, adhesion, and thermal stresses. Typically, micro moulds involve geometrically textured patterns or features such as linear ridges, pillars, channels, and holes, the characteristic dimensions of which range from 10 to 300 μm. Realistically complex mould designs, containing precision micro features (enhanced fillet radius and positive draft angle) and high surface quality, are presented in this work. Electropolishing based on forward pulse currents (PC) has been used to shape and polish Ni micro moulds that contain sets of micron-scaled linear ridges and star patterns in order to ease the separation of moulded polymeric parts from the metallic mould during ejection and demoulding. The use of forward pulsed currents improved the mould design by increasing the fillet radii and draft angle while keeping the surface roughness low and maintaining a good surface shine. An optimization study of forward PC using a green solution of nickel sulfamate varied EP times (0–70 min) and duty cycles (40, 50, 60, and 70%) at a process conditions of 2.8 V, 50 °C, and 250 rpm. The best topographical and morphological changes were observed for a typical microfluidic channel (w × h, 100 × 110 μm) with an EP time of 70 min and 50% duty cycle: fillet radius increased by 3.8 μm, draft angle by 3.3°, and the channel width reduced by 11.4% while surface roughness changed by 8.6% and surface shine improved by 48.9%. Experimental validation was performed using hot embossing wherein the electropolished Ni mould replicated the micro channels and star patterns in PMMA chips with notably fewer burrs, material pile up, and no feature distortion. Moreover, there was a reduction in the side wall roughness of micro channels in PDMS casting with electropolished Ni mould by 16%. Hence, this work presents a significant scientific contribution to improving the efficiency of micro mould tools and reduces the defects caused by friction and adhesion in replicated polymeric parts.
