pps proceeding - Abstract Preview
pps proceeding
Symposium: S04 - Injection molding
Oral Presentation
 
 

Optimization of micro-injection molding replication for quick response code applications

Regi Francesco (1)*, Doest Mads Emil Brix (2), Li Dongya (1), Zhang Yang (1), Frisvad Jeppe Revall (2), Tosello Guido (1)

(1) DTU Mechanical Engineering - Copenhagen - Denmark, (2) DTU Compute - Copenhagen - Denmark

Micro-structured surfaces have been increasingly used to embed functional properties such as optical electrical conductivity, etc, on parts and products. Replication techniques, like injection moulding and hot embossing are commonly used for mass production of those. In this project, directional optical properties were achieved with a microstructure composed of a close array of ridges, defined by a constant width and by the angle with respect to the normal of the generative surface. Under constrained lighting, the reflectance was maximized from a certain viewing angle and direction, and minimized from its horizontally orthogonal position. The purpose generated quick response codes that could be easily scanned by means of commercially available software. The ridges were 1.2 mm long, 0.2 mm wide and with a 10˚ slope angle, for a depth of about 30 µm. Each code was defined by 10x10 pixels, each one composed of 6 ridges, and was machined on an injection molding insert. The insert was replicated using black Acrylonitrile Butadiene Styrene (ABS). The final functionality was strongly related to the replication quality of the ridges. As such, optimized injection molding parameters were required. To evaluate the functionality, i.e. the generated light contrast from contingent microridges, the replicates were characterized by means of a robot assisted vision system, provided of a light source and a camera, used as a gonioreflectometer. The contrast was then correlated to the replication quality, i.e. the deviation of three defining parameters of the structures from the mould insert, thus determining the best processing conditions. The results showed that high injection speed, high mold temperature and high packing pressure were required to achieve proper functionality and that large variations in the surface functional behavior were present even for small differences between the parts.