Three-level hierarchical micro/nanostructures on biopolymers by injection moulding using low-cost polymeric inlays

Abstract

The industrial interest in the patterning of polymeric surfaces at the micro/nanoscale to include new functionalities has considerably increased during the last years. Hierarchical organization of micro/nanometric surface textures yields enhanced functional properties such as hydrophobicity, hydrophilicity, antibacterial activity, and optical or chromatic effects to cite some. While high accuracy methods to pattern hierarchical surfaces at the nanoscale have been developed, only some of them have been applied for high volume manufacturing with limited success, mainly because they rely on the use of expensive machinery and moulds or complicated inserts. Therefore, a method using low cost recyclable tooling and process conditions applicable to high-volume manufacturing is currently missing. In this work, a scalable and low-cost method to replicate hierarchical micro/nanostructured surfaces on plastic films is presented, which can be latter used as inlays for injection moulded parts with standard processing conditions. This method is used to demonstrate the feasibility of replicating three level hierarchical micro/nano textured surfaces using recyclable bio-based polymers (of high relevancy in the current plastic pollution context) achieving replication ratios above 90%, comparing the replication results with those obtained in polypropylene. The presence of the micro/nanotextures substantially increases the contact angle of all the polymers tested, yielding values higher than 90° in all the cases. Also, various mechanical properties of the replicated parts for all the polymers injected are characterized one and thirty days after the samples were manufactured, showing fairly constant values. This highlights the validity of the replicated surfaces, regardless of the biopolymers special crystallization characteristics.