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Effect of processing parameters, antistiction coatings, and polymer type when injection molding microfeatures
Author(s) -
Yoon SungHwan,
Cha NamGoo,
Lee Jun S.,
Park JinGoo,
Carter David J.,
Mead Joey L.,
Barry Carol M.F.
Publication year - 2010
Publication title -
polymer engineering and science
Language(s) - English
Resource type - Journals
SCImago Journal Rank - 0.503
H-Index - 111
eISSN - 1548-2634
pISSN - 0032-3888
DOI - 10.1002/pen.21541
Subject(s) - materials science , microscale chemistry , mold , thermoplastic , thermoplastic polyurethane , composite material , coating , polymer , scanning electron microscope , molding (decorative) , polycarbonate , polydimethylsiloxane , flatness (cosmology) , elastomer , mathematics education , mathematics , physics , cosmology , quantum mechanics
Thermoplastic polyurethane (TPU) and silicon tooling with microscale features on its surface was employed to investigate the impact of three factors on the quality of injection molded microscale features: (1) optimized process parameters, (2) use of a more flexible thermoplastic material, and (3) used as an antistiction coating. The molded parts and tooling surface were characterized by atomic force, confocal, and scanning electron microscopy. Although both improved filling of the tooling trenches, higher mold temperatures significantly enhanced replication, but faster injection velocities contributed moderately to replication quality. With medium aspect ratio (2.3:1) trenches, the antistiction coating doubled depth ratios, enhanced the edge definition and flatness of the features, and significantly reduced tearing of the features during ejection. The flexibility of the TPU permitted easier part ejection and left less polymer residue on the tooling surface in comparison to polycarbonate and other thermoplastic polymers. POLYM. ENG. SCI., 2010. © 2009 Society of Plastics Engineers