Chapter 2 - Replication Processes

Abstract

This chapter provides an overview of the various kinds of processes and technologies used for the replication of microstructured molds. Each of these replication processes is specified for a special kind of molded part and uses different polymers or different molding windows of the same polymer. Therefore, all these processes are not in competition with each other but are rather more complementary in replicating a wide range of microstructures with different properties for different applications. The chapter first gives a short listing of all processes and then specifies the criterions that are used to characterize each process. Further, each process is described briefly, including the process steps, the technology, the polymers suitable for molding, and the cost effectiveness. Further, the advantages and disadvantages of each process are discussed. Replication processes for macroscopic molded parts are well established in industrial use. These processes are highly automated and optimized for a large number of molded parts fabricated by short cycle times. Reaction molding technology is one of the established replication technologies on a macroscopic scale. Microinjection molding is another most established and automated process of all processes described in the chapter. Thermoforming is also a well-known replication process for macroscopic dimensions. In addition, nanoimprint technologies are used which are parts of next generation lithography with the aim to develop new structuring methods for the patterning of nanostructures. Finally, this chapter summarizes and compares the characteristics of the replication processes.