Microinjection molding of light‐guided plates using LIGA‐like fabricated stampers

Abstract

This investigation explores the microinjection molding of light-guided plates (LGPs) using lithography, electroplating, and molding (LIGA)-like fabricated stampers. The 3.5-in.LGP has a thin wall (0.76 mm) and micron-sized features of truncated pyramidal prisms (70 lm wide and 38.3 lm deep, with a vertex angle of 70.5) and v-grooves (9.8 lm deep). Stampers for LGP injection molding (IM) are fabricated precisely by combining the anisotropic wet etching of silicon-on-insulation wafers with electroforming.LGPs must have multiple quality characteristics, such as good replication effects on microfeatures and flatness of the plate. In this study, the Taguchi method and gray relational analysis are adopted to optimize the microinjection molding parameters. Various IM parameters, including mold temperature, melt temperature, holding pressure, and injection speed, are considered. Experimental results demonstrate that mold temperature and holding pressure dominate the performance. Gray relational analysis and the Taguchi method can be used to determine the optimal process parameters for LGP molding.

Preparation of a Microprism Ni-Ceo2Nanocomposite Mold by Electroforming

“…Electroforming has been applied to fabricate many highly precise products, such as compact disks, stampers, and masters for non-spherical mirrors [5][6][7]. However, the lower microhardness of electroformed materials has prevented its wider usage in general plastics and optical mold making.…”

Replication of surface micro‐features using variothermal injection molding: Application to micro‐fluidics

“…The literature in this area is extensive and here we highlight the key conclusions. Many studies have taken a design‐of‐experiments approach to investigate the relative importance of the various injection molding process parameters, but, since each is usually varied at only two or three levels, these provide limited insight into the detailed mechanisms of action and interaction . In the following paragraphs, the important process parameters are identified, with an outline of how and why they influence replication, illustrated by selected citations.…”

Theoretical analysis and numerical modeling of the evolution mechanism of polymer melt unstable flow in two‐dimensional ultrasonic‐assisted micro‐injection molding

“…[6][7][8] The researchers mainly increased the filling capability of polymer melt in the micro cavity and improved the mold filling quality by optimizing the parameters of micro-injection molding such as mold temperature, melt temperature, injection speed, and holding pressure, and so on. [9][10][11][12][13] But the excessively high-injection molding parameters made enormous demands on injection machine performance, and mold design and manufacturing, which increased the cost of micro-injection molding and might cause some molding defects, such as oxidation degradation, air traps, and warping deformation, and so on. [14][15][16] The flow property of polymer melt is hard to improve due to the high-heat dissipation rate in the microinjection molding, and some molding defects increase with the improvement of molding parameters.…”