Replicative manufacturing of metal molds for low surface roughness polymer replication

Sebastian Kluck; Leonhard Hambitzer; Markus Mader; Frederik Kotz-Helmer; Bastian E. Rapp

doi:10.1117/12.3002244

12 March 2024 Replicative manufacturing of metal molds for low surface roughness polymer replication

Sebastian Kluck, Leonhard Hambitzer, Markus Mader, Frederik Kotz-Helmer, Bastian E. Rapp

Proceedings Volume 12837, Microfluidics, BioMEMS, and Medical Microsystems XXII; 1283709 (2024) https://doi.org/10.1117/12.3002244
Event: SPIE BiOS, 2024, San Francisco, California, United States

Abstract

Polymers are still gaining a lot of interest in the field of optics and sensor technology. Structuring of these components is usually done using high-throughput manufacturing processes such as injection molding, allowing excellent shaping quality and high degree of automation. However, tool production for these tool-based manufacturing methods tends to be time consuming and expensive, limiting the flexibility of these processes. We developed a novel process enabling the fabrication of metallic insets with optical surfaces and structures at the micrometer scale. This involves utilizing high-temperature-stable fused silica glass bodies as molds for metal casting. The process enables the processing of metal alloys such as bronze, brass, and cobalt-chromium at temperatures reaching up to 1400 °C. The metal replications achieve resolutions in the single-digit micrometer range and exhibit a surface roughness in the order of a few nanometers. The manufactured mold tools were successfully tested in a polymer injection molding process.

Conference Presentation

Citation Download Citation

Sebastian Kluck, Leonhard Hambitzer, Markus Mader, Frederik Kotz-Helmer, and Bastian E. Rapp "Replicative manufacturing of metal molds for low surface roughness polymer replication", Proc. SPIE 12837, Microfluidics, BioMEMS, and Medical Microsystems XXII, 1283709 (12 March 2024); https://doi.org/10.1117/12.3002244

ACCESS THE FULL ARTICLE

INSTITUTIONAL
Select your institution to access the SPIE Digital Library.

SELECT YOUR INSTITUTION

PERSONAL
Sign in with your SPIE account to access your personal subscriptions or to use specific features such as save to my library, sign up for alerts, save searches, etc.

PERSONAL SIGN IN

No SPIE Account? Create one

PURCHASE THIS CONTENT

SUBSCRIBE TO DIGITAL LIBRARY

50 downloads per 1-year subscription

Members: $195

Non-members: $335 ADD TO CART

25 downloads per 1 - year subscription

Members: $145

Non-members: $250 ADD TO CART

PURCHASE SINGLE ARTICLE

Includes PDF, HTML & Video, when available