Title: Challenges in high accuracy surface replication for micro optics and micro fluidics manufacture

Authors: Guido Tosello; Hans Nørgaard Hansen; Matteo Calaon; Stefania Gasparin

Addresses: Department of Mechanical Engineering, Technical University of Denmark, Produktionstorvet, DTU building 427A, DK-2800 Kgs. Lyngby, Denmark ' Department of Mechanical Engineering, Technical University of Denmark, Produktionstorvet, DTU building 427A, DK-2800 Kgs. Lyngby, Denmark ' Department of Mechanical Engineering, Technical University of Denmark, Produktionstorvet, DTU building 427A, DK-2800 Kgs. Lyngby, Denmark ' LEGO System A/S, Åstvej, DK-7190 Billund, Denmark

Abstract: Patterning the surface of polymer components with microstructured geometries is employed in optical and microfluidic applications. Mass fabrication of polymer micro structured products is enabled by replication technologies such as injection moulding. Micro structured tools are also produced by replication technologies such as nickel electroplating. All replication steps are enabled by a high precision master and high reproduction fidelity to ensure that the functionalities associated with the design are transferred to the final component. Engineered surface micro structures can be either distributed, e.g., to create an optical pattern, or discretised, e.g., as micro channels for fluids manipulation. Key aspects of two process chains based on replication technologies for both types of micro structures are investigated: lateral replication fidelity, dimensional control at micro scale, edge definition. The parts investigated are a micro retroreflector and a micro fluidic system, typical applications of injection moulded parts with micro structured functional surfaces.

Keywords: injection moulding; tooling; micro-optics; microfluidics; surface replication; optics; fluidics; surface patterning; polymer components; microstructure; retroreflectors.

DOI: 10.1504/IJPTECH.2014.060612

International Journal of Precision Technology, 2014 Vol.4 No.1/2, pp.122 - 144

Published online: 30 Apr 2015 *

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