研究目的
To develop and characterize a new process chain for the versatile and cost-effective production of sub-micron textured plastic parts using laser ablation, focusing on the generation of different sub-micron structures on the surface of a mold and their replication through micro-injection molding.
研究成果
The study successfully developed a process chain for the cost-effective production of sub-micron textured plastic parts using laser ablation and micro-injection molding. The results show that the presence of a pattern increases surface functionality, with maximum water contact angle increases of 20% and 17% for PMMA and PS samples, respectively. The functionalization was affected by the polymer temperature, depending on melt viscosity. The findings suggest that keeping a lower mold temperature leads to a decrease in manufacturing costs both from energy consumption and cycle time savings.
研究不足
The study is limited to the use of specific polymers (PS and PMMA) and does not explore the full range of potential materials. The laser texturing process, while fast, may have limitations in terms of the uniformity and depth of structures achievable at higher beam incidence angles. The replication accuracy and functionalization are highly dependent on mold temperature, which may limit the process's applicability in scenarios where temperature control is challenging.
1：Experimental Design and Method Selection:
The study involved the generation of different sub-micron structures on the surface of a mold using femtosecond laser ablation and vario-thermal micro-injection molding. The methodology included laser ablation for surface texturing and micro-injection molding for replication.
2：Sample Selection and Data Sources:
Mold inserts were machined and polished to obtain a smooth surface finish before laser patterning. Two polymers, polystyrene (PS) and poly-methyl methacrylate (PMMA), were selected for the experimental work.
3：List of Experimental Equipment and Materials:
A femtosecond laser source (Satsuma, Amplitude Systems) was used for laser patterning. A micro injection molding machine (MicroPower 15, Wittmann-Battenfeld GmbH) was used for the μIM experiments. Confocal profilometer (3D S Neox, Sensofar), SEM (FEI, Quanta 400, Thermo Fisher Scientific), and AFM (CP II, Veeco Digital Instruments, Bruker) were used for surface characterization.
4：Experimental Procedures and Operational Workflow:
The laser beam was focused using a telecentric lens and moved with a galvanometer scanner over the insert surface. The mold temperature was varied from 40 to 120°C. The replication performance was evaluated considering the functionality of the manufactured plastic parts.
5：Data Analysis Methods:
The morphology of the sub-microstructures was characterized using SEM and AFM. The wetting properties were evaluated from contact angle measurements.
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