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Open AccessArticle

Efficient and Precise Micro-Injection Molding of Micro-Structured Polymer Parts Using Micro-Machined Mold Core by WEDM

1
School of Mechanical and Electrical Engineering, Shenzhen Polytechnic, Shenzhen 518055, China
2
Guangdong Provincial Key Laboratory of Micro/Nano Optomechatronics Engineering, College of Mechatronics and Control Engineering, Shenzhen University, Shenzhen 518060, China
*
Authors to whom correspondence should be addressed.
Polymers 2019, 11(10), 1591; https://doi.org/10.3390/polym11101591
Received: 28 July 2019 / Revised: 26 September 2019 / Accepted: 27 September 2019 / Published: 29 September 2019
(This article belongs to the Special Issue Micro- and Nano-Fabrication Approaches for Polymers)
In this paper, micro-structured polymer parts were efficiently and accurately fabricated by micro-injection molding using a micro-structured mold core machined by wire electrical discharge machining (WEDM). The objective was to realize low-cost mass production and manufacturing of micro-structured polymer products. The regular micro-structured mold core was manufactured by precise WEDM. The micro-structured polymer workpieces were rapidly fabricated by micro-injection molding and the effects of the micro-injection molding process parameters on replication rate and surface roughness of micro-structured polymers were systematically investigated and analyzed. It is shown that the micro-structured polymer can be rapidly and precisely fabricated by the proposed method. The experimental results show the minimum size machining error of the micro-structured mold core and the maximum replication rate of micro-formed polymer were 0.394% and 99.12%, respectively. Meanwhile, the optimal micro-injection molding parameters, namely, jet temperature, melt temperature, injection velocity, holding pressure and holding time were 195 °C, 210 °C, 40 mm/min, 7 Mpa and 5 s, respectively. The surface roughness Ra at the groove bottom and top of the micro-structured polymer workpieces achieved minimum values of 0.805 µm and 0.972 µm, respectively. View Full-Text
Keywords: micro-structure; polymer; micro-injection molding; mold; WEDM micro-structure; polymer; micro-injection molding; mold; WEDM
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MDPI and ACS Style

Liao, Q.; Zhou, C.; Lu, Y.; Wu, X.; Chen, F.; Lou, Y. Efficient and Precise Micro-Injection Molding of Micro-Structured Polymer Parts Using Micro-Machined Mold Core by WEDM. Polymers 2019, 11, 1591.

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