Study on the replication quality of micro-structures in the injection molding process with dynamical tool tempering systems

The injection molding of micro-structures is a promising mass-production method for a broad range of materials. However, the replication quality of these structures depends significantly on the heat flow during the filling stage. In this paper, the filling and heat transfer of v-groove and random structures below 5 μm is investigated with the help of an AFM (atomic force microscope) and thermo couples. A numerical model is developed to predict the filling of surface structures during the filling and packing stage. The model implies the use of simple fully developed flow models taking the power-law material model into account. This permits investigation into which ways several processing parameters affect the polymer flow in the surface structures. The mold wall temperature, which has significant effects on the polymer flow, is varied by using a variothermal mold temperature control system to validate the model proposed.