Abstract
Nanopattern replication of complex structures by plastic injection is a challenge that requires simulations to define the right processing parameters. Previous work managed to simulate replication for single cavities in 2D and 3D, showing high performance requirements of CPU to simulate periodic trenches in 2D. This paper presents two ways to approach the simulation of replication of complex 3D hydrophobic surfaces. The first approach is based on previous CFD Ansys Fluent and compared to FE based CFD Polyflow software for the analysis of laminar flows typical in polymer processing and glass forming as well as other applications. The results showed that Polyflow was able to reduce computing time from 72 h to only 5 min as desired in the project. Furthermore, simulations carried out with Polyflow showed that higher injection and mold temperature lead to better replication of hydrophobicity in agreement with the experiments. Polyflow simulations are proved to be a good tool to define process parameters such as temperature and cycle times for nanopattern replication.
Highlights
The use of nanotextured surfaces is increasing in many products due to their wide field of applications
This paper presents two ways to approach the simulation of replication of complex 3D hydrophobic surfaces
The first approach is based on previous computational fluid dynamics (CFD) Ansys Fluent and compared to finite elements (FE) based CFD Polyflow software for the analysis of laminar flows typical in polymer processing and glass forming as well as other applications
Summary
The use of nanotextured surfaces is increasing in many products due to their wide field of applications. Such surfaces are usually inspired from nature. One of the best-known structures is the Lotus leaf effect [6] and there are several articles that intend to explain and copy the lotus effect [7]. Injection molding is a low production cost manufacturing process [8] able to replicate many geometries due to the phase change of the molded material. Nanostructured surfaces are a possible target for this manufacturing process. It is challenging to copy the texture due to the solidification of the polymer before reaching 100% of the mold [9]
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