Large-area polymer microstructure replications through the hot embossing process using modular moulding tools

Abstract

In recent years, hot embossing of polymer microstructures has developed from a simple laboratory technique to an established research and development (R&D) technology. A multitude of technical applications demonstrate the high performance of this replication technique that does not yield only first prototypes. Still, this technology has not yet been recognized as a manufacturing process by industry. The present article will describe a large-area moulding tool that can be integrated easily in existing hot embossing machines owing to its modular character. The mould insert used consists of several modules that can be exchanged for a variety of applications or in cases of partial damage. The moulding tool has already been employed in a newly developed machine designed for integration in a process chain. The equipment controls and operator panels of this machine are based on standard programmable logic controllers (PLCs) well established in manufacturing. This makes hot embossing more transparent, compatible, and hence reliable. Functioning and assembly of these components will be illustrated by a ‘dispensing well plate’ with outer dimensions of 127.8 mm × 85.5 mm, which are used to produce ambitious through-hole nozzle components. This continuous process chain will demonstrate that hot embossing is ready for industrial implementation.