Micro replication by injection-compression molding

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DOIResolve DOI: http://doi.org/10.3139/217.2264
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Journal titleInternational Polymer Processing
Pages288297; # of pages: 10
AbstractThe replication of polymeric microstructures on a flat surface is not easily achieved by conventional injection molding, because of the required micro-dimensional control and the stringent tolerances of most applications. Moreover, the flow behaviour of melts in micro cavities remains not well understood and challenging. On the other hand, injection-compression molding is an established process for the manufacturing of optical storage media, like compact discs (CD) or digital versatile discs (DVD), with grooves and pits at the micro-scale. The difficulties arise mainly from two sources: lack of adequate filling because of premature freezing of features with very small thicknesses and excessive deformation during ejection due to high friction at the polymer-metal interface. In this work, a study is carried out to investigate the effect of process parameters on the replication of various microstructures on a flat disk using microinjection-compression molding. A commercial microinjection molding machine has been used in the study. Two optical grade polymers poly(methyl methacrylate) (PMMA) and cyclic olefin polymer (COP) were used in conjunction with various mold inserts to reproduce the embedded microstructures. The dimensions of the microstructures on the inserts and molded parts were measured with a confocal profiler. A transcription ratio was defined to assess the quality of the replication. The design of experiment (DOE) method was used to obtain correlations between the process parameters and the development of the microstructure during injection-compression molding.
Publication date
AffiliationNRC Industrial Materials Institute; National Research Council Canada
Peer reviewedNo
NRC number54268
NPARC number18371418
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Record identifier14a63bcc-a8d5-4640-981f-5286270da99f
Record created2011-08-03
Record modified2016-05-09
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