Injection Molding Nanoscale Features with the Aid of Induction Heating

During injection molding of micron or submicron scale features, incomplete filling frequently occurs, resulting from premature freezing of the polymer melt in contact with a cold mold. In order to overcome the filling difficulty without increasing the total cycle time, the mold surface temperature was raised rapidly by induction heating. A prototype mold insert with cooling channels was fabricated and integrated with a nickel stamp having nanoscale-grating structures. The nickel stamp surface was successfully heated from 25 to 258°C in 2.7 sec. Four different mold surface temperatures, 100, 150, 200 and 250°C, were tested to determine if the nanograting structures can be replicated with an optical quality cyclic olefin copolymer. Experimental results indicate that the nanocavities were successfully filled when the surface temperature reached 250°C, but mold release caused drag damages on the nanogratings. Further, coupled thermoelectromagnetic analyses were carried out to simulate the induction heating process of the nanostructured mold insert. The predicted surface temperature responses in general agree with the experimental ones and the simulation model can be used in the further development of process control and mold design in micro/nano molding.