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Injection molding of polymer micro- and sub-micron structures with high-aspect ratios

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Abstract

This work studies the injection molding characteristics of polymer micro- and sub-micron structures using demonstration mold inserts with micro- and sub-micron channels with high-aspect ratios. The effects of the injection molding parameters on the achievable aspect ratio of the micro- and sub-micron walls were investigated. Additionally, distinctive mold-filling behaviors and resulting defects were observed for various polymers, such as polymethyl methacrylate (PMMA), polypropylene (PP) and high-density polyethylene (HDPE). Experimental results reveal that the mold temperature determines the success of the injection molding of micro- and sub-micron walls. The satisfactory mold temperature for micro-injection molding significantly exceeds that for traditional injection molding. Moreover, the main injection pressure and the main injection time substantially affect the achievable aspect ratio of the micro- and sub-micron walls. Furthermore, unusual flow behaviors occur and poor molding results are obtained when PP and HDPE are used for micro-injection molding.

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Authors and Affiliations

  1. Department of Mechanical Engineering, National Chiao Tung University, 1001 Ta Hsueh Road, Hsinchu, 30010, Taiwan

    A.-C. Liou & R.-H. Chen

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  1. A.-C. Liou
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  2. R.-H. Chen
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Correspondence to R.-H. Chen.

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Liou, AC., Chen, RH. Injection molding of polymer micro- and sub-micron structures with high-aspect ratios. Int J Adv Manuf Technol 28, 1097–1103 (2006). https://doi.org/10.1007/s00170-004-2455-2

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  • DOI: https://doi.org/10.1007/s00170-004-2455-2

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