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

Influences of micro-ridges orientation and density on the replication of micro-structured surfaces by Injection Molding

Regi Francesco (1)*, Basso Alberto (1), Loaldi Dario (1), Kain Martin (1), Li Dongya (1), Zhang Yang (1), Tosello Guido (1)

(1) DTU Mechanical Engineering - Copenhagen - Denmark

In this project, directional optical properties were achieved with a microstructure composed of a close array of ridges, defined by their width and by the angle with respect to the structured surface. Under constrained lighting, the reflectance generated by the micro ridges, was maximized from a certain viewing angle and minimized from its orthogonal position. The purpose was the generation of contrast based 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 pixel and each pixel was composed by 6 ridges. This study investigated the replication of the microridges in the injection molding process. The effect of the ridge orientation with respect to the polymer flow front direction, as well as the contour effect of the surrounding pixels were analyzed using design of experiments. To this scope, 4 injection molding inserts have been milled. One insert presented the full structures, whilst only 9 pixels were machined at three distances from the gate on the three remaining inserts. In this way, the contour effect was analyzed by comparing replication of individual pixels vs pixels included in the data matrix array. The inserts were subsequently replicated using Acrylonitrile butadiene styrene (ABS). Inserts and replicates were characterized using an Olympus Lext OLS4100 Laser Confocal microscope. The results showed that ridges parallel to the flow on the replicates had better replication accuracy. However, the ridges far from the gate showed less sensitivity regarding to their orientation and were generally more accurately replicated. Furthermore, the isolated pixels had worse replication if compared with the corresponding surrounded pixel for all the involved positions.