Micro Injection Molding: New Solutions for Manufacturing of Microscale and Nanoscale Plastic Products

Overview

Micro injection molding is a recent technology used to manufacture plastics products characterized by either dimensions in the micrometer range or by the presence of micro and/or nano features on their topography. Its main applications are in the field of biomedics, microfluidics, electronics and sensors. This course will provide a comprehensive overview of the micro injection molding process, covering all aspects related to machines, mold design, processing and micro-parts characterization. The difference with conventional injection molding will be highlighted to provide an understanding of micro molding peculiarities. In addition, the course will cover the fundamentals of process control and optimization for micro injection molding. Different approaches to the manufacturing of microscale and nanoscale plastic products will be presented. Attendees are expected to leave the seminar with a complete understanding of the potential of this technology in several fields of application.

Content

Day 1

Introduction

• What is micro injection molding?
• Micro components vs. micro-structured components
• Differences with conventional injection molding

Applications

• Industrial field of applications
• Real applications
• Advantages and motivation for micro molding

Process Chain for Micro Molding

• Micro molding as a replication technology

Workshop

• CAE simulation for micro injection molding

DAY 2

Machinery

• Molding machines for micro molding applications

Mold Design for Micro Injection Molding

Tooling Technologies

• Micro milling
• Micro-electro discharge machining
• Lithography
• Laser

Workshop

• Experimental micro injection molding
• Comparison with conventional molding
• Process parameters optimization

DAY 3

Process Monitoring and Optimization

• Effect of process parameters
• Pressure and temperature monitoring
• Flow visualization

Metrology for Micro Molding

• Optical profilometry
• Scanning Electron Microscopy (SEM)
• X-Ray Computed Tomography

Workshop

• Metrological characterization of micro molded parts using different technologies (optical profilometer, Scanning Electron Microscope)
• Common defects in micro molded parts