Laser structuring of metallic mold inserts by using μs, ns, and ps-laser ablation

Abstract

Bio-inspired surfaces targeting functional characteristics such as anti-reflectivity, self-cleaning effects or a drag reduction are of significant interest to industry. In this feasibility study, process chains for the mass production of so-called shark skin structured surfaces are investigated. Due to their drag reduction properties, such bio-inspired surfaces are of relevance to a number of applications in which particular aqua- and aerodynamic characteristics are required. The design of the shark skin structure relies on a bio-mimetic analytical model to generate the 3D surface model necessary to achieve the targeted surface functionality. The process chains presented combine laser ablation as a method for micro structuring masters for high throughput replication employing injection molding. In particular, three different process chains that rely on micro second (μs), nano second (ns) and pico second (ps) laser ablation systems to pattern mold inserts were investigated. Then, these inserts were integrated into a tool for micro injection molding and replication trials were carried out. The results show that all three laser sources can be utilized to create this kind of micro cavities. This research indicates that these micro structures can be replicated successfully, but further work is required to optimize the replication and laser structuring process.