Precision electroforming of nickel nanocomposite mould for defects-free demoulding in polymer micro replication: Surface properties, performance validation and mould release mechanism

Abstract

Microinjection moulding and micro/nano hot embossing are two promising manufacturing processes for the mass production of polymer workpieces with micro/nano structures. However, adhesion and friction between polymer workpieces and mould tools can cause structural distortion and surface damage. Besides, the nickel mould's lifetime is limited by its low hardness and wear resistance. To address these issues, we proposed a new methodology to codeposit micro/nanomaterials into nickel mould for microhardness enhancement and effective mould release. In this study, polytetrafluoroethylene (PTFE) microparticles, tungsten disulfide (WS2) and molybdenum disulfide (MoS2) nanosheets were incorporated into nickel mould by electroforming. Cobalt was added as a secondary phase to improve the microhardness and wear resistance of the composite mould. The result indicated that WS2 nanosheets achieved the most significant performance enhancement among three micro/nanomaterials, represented as the microhardness improved from 191 HV for pure nickel to 564 HV for nickel/WS2 nanocomposites, along with the coefficient of friction (COF) against the polymethyl methacrylate (PMMA) pin reducing from 0.72 to 0.10 in the initial stage of the sliding. With the incorporation of micro/nanomaterials, the wettability altered from hydrophilic for pure nickel to hydrophobic for the composite moulds. The study shows that the addition of cobalt improved the microhardness of the composite moulds but meanwhile induced more adhesive wear during the pin-on-disc test. Finally, a nickel/WS2 nanocomposite mould is successfully fabricated via electroforming with feature sizes from 70 to 180 μm and its lubricating properties are validated by micro hot embossing PMMA microfluidic chips with good surface quality and structural integrity.