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Fabrication of Micro-Structured Polymer by Micro Injection Molding Based on Precise Micro-Ground Mold Core
Yanjun Lu1, Fumin Chen2, Xiaoyu Wu3
1Guangdong Provincial Key Laboratory of Micro/Nano Optomechatronics Engineering, College of Mechatronics and Control Engineering, Shenzhen University, Shenzhen 518060, China. luyanjun@szu.edu.cn.
Micromachines
|April 19, 2019
Summary
Precise micro-grinding enables mass production of micro-structured polymers via micro injection molding. Higher mold accuracy directly improves polymer filling rates, achieving 99.30% with optimal parameters.
Area of Science:
- Materials Science
- Manufacturing Engineering
- Polymer Science
Background:
- Micro-structured polymer components are crucial for advanced applications.
- Mass production of these components requires precise mold fabrication.
- Micro injection molding is a key manufacturing technique for micro-structures.
Purpose of the Study:
- To develop a precise micro-grinding method for fabricating micro-grooved mold cores.
- To investigate the relationship between mold accuracy and micro-structured polymer formation.
- To optimize micro injection molding parameters for high-fidelity replication.
Main Methods:
- Fabrication of micro-grooved mold cores using precise micro-grinding.
- Characterization of 3D topographies and surface roughness of mold cores and polymers.
- Micro injection molding of polymer components using fabricated molds.
- Analysis of machining accuracy, mold surface roughness, and polymer filling rates.
- Investigation of micro injection molding parameters (injection pressure, melt temperature) on filling rates.
Main Results:
- Achieved high form accuracy of 4.05 µm for micro-grooved mold cores.
- Reached a maximum micro-structured polymer filling rate of 99.30%.
- Demonstrated a positive correlation between mold machining accuracy and polymer filling rate.
- Identified injection pressure as the most influential parameter, and melt temperature as the least influential on filling rate.
Conclusions:
- Precise micro-grinding is an effective method for mass-producing micro-structured polymer components.
- Optimized micro injection molding parameters significantly enhance the replication fidelity of micro-structures.
- The study provides a pathway for high-accuracy manufacturing of micro-structured polymer parts.
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