Product Fingerprints for the Evaluation of Tool/Polymer Replication Quality in Injection Molding at the Micro/Nano Scale

Loaldi, Dario; Regi, Francesco; Li, Dongya; Giannekas, Nikolaos; Calaon, Matteo; Zhang, Yang; Tosello, Guido

doi:10.1007/s41871-021-00105-7

Cited by 9 publications

(1 citation statement)

References 27 publications

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“…An important requirement in micro IM is the assessment of the replication of the micro-injected parts. To this end, optical methods can be adequately selected depending on the specific micro/nano features characterizing the parts [20]. Furthermore, the definition of the relation linking IM process parameters and surface roughness is also relevant, as it can provide useful insight towards the optimization of process and products.…”

Section: Introductionmentioning

confidence: 99%

Quality Definition in Micro Injection Molding Process by Means of Surface Characterization Parameters

2022

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Quality evaluation of micro injection molded products is a complex task, in particular when instruments basing on contact methods are used and issues in measurements could arise due to the contact tool dimension not fitting well with extremely narrow features. Therefore, in these cases, optical methods may be preferred for the evaluation of molded products’ dimensions and surface quality, especially for parts devoted to applications requiring functional purposes. In this context, the present paper proposes the use of surface parameters as a quality index for the evaluation of both the micro injection molding process and the resulting products. To this aim, two experimental procedures were implemented to allow for: (i) the evaluation of the most suitable surface parameters identified in relation to the process parameters; (ii) comparisons of the surface parameters findings with those obtained by classic dimensional quantity via a designed experimental plan (DoE). The results show that the surface parameters, evaluated in critical areas of the components, can ensure reliable estimates for the surface quality of the molded parts and can be preferred in comparison to linear measurements.

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Section: Introductionmentioning

confidence: 99%

Quality Definition in Micro Injection Molding Process by Means of Surface Characterization Parameters

2022

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Toward Defect‐Free Nanoimprinting

Guan,

Huang,

Song

et al. 2024

Small

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Nanoimprinting large‐area structures, especially high‐density features like meta lenses, poses challenges in achieving defect‐free nanopatterns. Conventional high‐resolution molds for nanoimprinting are often expensive, typically constructed from inorganic materials such as silicon, nickel (Ni), or quartz. Unfortunately, replicated nanostructures frequently suffer from breakage or a lack of definition during demolding due to the high adhesion and friction at the polymer‐mold interface. Moreover, mold degradation after a limited number of imprinting cycles, attributed to contamination and damaged features, is a common issue. In this study, a disruptive approach is presented to address these challenges by successfully developing an anti‐sticking nanocomposite mold. This nanocomposite mold is created through the co‐deposition of nickel atoms and low surface tension polytetrafluoroethylene (PTFE) nanoparticles via electroforming. The incorporation of PTFE enhances the ease of polymer release from the mold. The resulting Ni‐PTFE nanocomposite mold exhibits exceptional lubrication properties and a significantly reduced surface energy. This robust nanocomposite mold proves effective in imprinting fine, densely packed nanostructures down to 100 nm using thermal nanoimprinting for at least 20 cycles. Additionally, UV nanoimprint lithography (UV‐NIL) is successfully performed with this nanocomposite mold. This work introduces a novel and cost‐effective approach to reusable high‐resolution molds, ensuring defect‐reduction production in nanoimprinting.

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Direct 3D printing functional surfaces stacked with microstructured filaments

Han,

Sun,

et al. 2024

Additive Manufacturing

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Product Fingerprints for the Evaluation of Tool/Polymer Replication Quality in Injection Molding at the Micro/Nano Scale

Cited by 9 publications

References 27 publications

Quality Definition in Micro Injection Molding Process by Means of Surface Characterization Parameters

Quality Definition in Micro Injection Molding Process by Means of Surface Characterization Parameters

Toward Defect‐Free Nanoimprinting

Direct 3D printing functional surfaces stacked with microstructured filaments

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