Abstract
Precision injection moulding of miniaturised products with microfeatures, such as channels for microfluidic applications, poses the greatest challenges in terms of tooling technology and process optimisation. The injection moulding process window of polypropylene was validated using a metrological approach for the production of a microfluidic substrate. The dimensional accuracy of microchannels that are 48 μm wide and 110 μm deep and the quality surface topography replication (surface roughness from 30 to 360 nm) were investigated using non-contact measuring instruments, such as an optical coordinate measuring machine and a white light interferometer respectively. The effect of the dimensional scale range on the micro-/nanofeature replication was evaluated, and it was found to be the dominant parameter if compared with the effect of the other process related parameters investigated (melt and mould temperatures and injection speed).
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