Polymeric nanofeatures of 100 nm using injection moulding for replication

Abstract

The filling efficiency of replicated nanofeatures made with polymers using injection moulding with various moulding factors was investigated. Two simple calibration gratings with nanofeatures of 105 nm and 130 nm, respectively, were used as mould inserts to replicate nanofeatures by means of a custom-made injection machine. Nanofeatures made with polypropylene (PP), polystyrene (PS), polycarbonate (PC) and polymethylmethacrylate (PMMA) were tested because of differing viscosities and shrinkages in polymers. The results show that the surface configuration of the polymeric nanofeatures with low melt viscosity could be moulded well, while nanofeatures with high melt viscosity exhibited higher tolerance in depth. However, the moulding depth of nanofeatures could be effectively improved when mould temperature and forming pressure were higher. It was found that the reproducibility of the nanofeatures in large numbers could be replicated well after melt and mould temperatures became stable during moulding.

Study on the replication quality of micro-structures in the injection molding process with dynamical tool tempering systems

“…Therefore, some authors have already presented their experimental results in the replication of different surface structures (Huang 2007;Giboz et al 2007;Yao and Kim 2002;Mosaddegh and Angstadt 2008;Pranov et al 2006;Xu et al 2005;Mönkkönen et al 2002). Some of them have also carried out numerical results with micro scale factors like wall slip and mold surface roughness, and compared their results to experimental tests.…”

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

“…Taking into account the results of other experimental studies (Huang, 2007;Monkkonen et al, 2002;Sha et al, 2006;Tosello, Gava, Hansen, & Lucchetta, 2010), some preliminary trials were conducted to identify an appropriate combination of parameter settings and thus to produce replicas of required quality.…”

Nanostructured Free‐Form Objects via a Synergy of 3D Printing and Thermal Nanoimprinting

“…Since injection molding is a replication process, the resolution and the geometry of molded products are, in priori, defined by the mold inserts. High resolution dimension is well established in the injection molding of compact disc (CD) and digital video disc (DVD), which are flat and planar products . Similarly, the existing publications on injection molding of polymer micro‐ and submicron structures were achieved using mold inserts fabricated by 2D lithographic processes, meaning that the geometry of the produced parts are also limited to flat and planar format.…”

“…High resolution dimension is well established in the injection molding of compact disc (CD) and digital video disc (DVD), which are flat and planar products. [23][24][25] Similarly, the existing publications on injection molding of polymer micro-and submicron structures were achieved using mold inserts fabricated by 2D lithographic processes, [25][26][27] meaning that the geometry of the produced parts are also limited to flat and planar format. Injection molding of sub-100 nm nanostructures with aspect ratio of 2.5 pillars using flat nickel mold inserts has been reported.…”