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Updated: Jul 11, 2026

Rapid and Low-cost Prototyping of Medical Devices Using 3D Printed Molds for Liquid Injection Molding

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Published on: June 27, 2014

Sessile Liquid Features as Molds for Silicone Elastomers.

Takamichi Shimosaka¹, Thomas J McCarthy¹

¹Polymer Science and Engineering Department, University of Massachusetts, Amherst, Massachusetts 01003, United States.

Langmuir : the ACS Journal of Surfaces and Colloids

|April 10, 2020

Summary

Chemically patterned substrates with sessile liquid drops create 3D molds for polymer imprinting. Glycerol proved most controllable, enabling shape adjustment via condensation/evaporation for reproducible microstructuring.

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Area of Science:

Materials Science
Surface Chemistry
Microfabrication

Background:

Chemically patterned substrates with liquids form 3D contoured surfaces.
These surfaces can serve as molds for polymer imprinting via resin curing.
Reproducibility depends on substrate chemistry, liquid properties, and curing conditions.

Purpose of the Study:

Investigate liquid-based molding for polymer imprinting.
Evaluate different liquids (water, glycerol, ethylene glycol oligomer, ionic liquid) for mold fabrication.
Assess factors influencing mold shape and imprinting success, focusing on silicone elastomer curing.

Main Methods:

Fabrication of patterned substrates with fluoroalkylsilyl monolayers.
Application of various liquids (water, glycerol, ethylene glycol oligomer, ionic liquid) to create sessile drops.
Room temperature platinum(0)-catalyzed curing of Sylgard 184 silicone elastomer against the liquid molds.
Analysis of liquid properties (vapor pressure, permeability, compatibility) and their impact on curing and feature shape.
Demonstration of shape control using condensation/evaporation with glycerol.

Main Results:

Water's vapor pressure and permeability in silicone were problematic but controllable via humidity.
An ionic liquid inhibited silicone curing but offered low vapor pressure for scalable coating studies.
An ethylene glycol oligomer showed compatibility and diffusion into the silicone.
Glycerol demonstrated excellent control, enabling shape adjustment through condensation/evaporation.

Conclusions:

Liquid-based molding offers a flexible and reproducible method for polymer microstructuring.
Liquid properties significantly influence mold performance and imprinting outcomes.
Glycerol is a promising liquid for controlled shape-morphing molds in microfabrication.