Design and application of a hybrid alignment platform for a double-sided hot embossing process

Abstract

Hot embossing is a novel technique for the cost-effective production of micro-parts. Misalignment between the top and bottom surfaces of a product that has double-sided microstructures reduces its functions. Most solutions involve repairing or reproducing the embossing mold, which increases the cost for the molding process. This study proposes a hybrid alignment platform that allows accurate positioning and angular alignment for the embossing processes. The hybrid alignment platform includes two units. The upper unit allows angular adjustment using a precision rotary table. The lower unit allows positional adjustment using two orthogonal micrometers. Calibration tests are conducted for a series of adjustment steps along the X, Y and C axis. Only one alignment step is necessary for each axis. The alignment platform allows rapid positioning and increases replicability. The hybrid mold adjustment platform is used to resolve a problem with gear misalignment and the problem of eccentricity in the production of micro-gears is effectively resolved.