Abstract
Ultrasonic hot embossing is a new process for fast and low-cost production of micro systems from polymer. Investment costs are on the order of 20.000 € and cycle times are a few seconds. Microstructures are fabricated on polymer foils and can be combined to three-dimensional systems by ultrasonic welding.
Highlights
The main reason why micro products from thermoplastic polymers are interesting as soon as a micro system goes into industrial applications is that fabrication costs are much less than for alternative processes
Ultrasonic hot embossing opens up a lot of new chances both for the development and fabrication of micro systems
Ultrasonic hot embossing is combined with ultrasonic welding
Summary
The main reason why micro products from thermoplastic polymers are interesting as soon as a micro system goes into industrial applications is that fabrication costs are much less than for alternative processes. The cycle time of both injection molding and hot embossing is within the range of a few minutes, because the entire tool needs to be heated up and cooled down again This is called a variotherm process which is required to fill all micro cavities in the mold. The problems of shrinkage and large cycle times are drastically reduced if, rather than the entire tool and the polymer being heated above glass transition temperature and cooled down again, only the part of a polymer foil which is to be adapted to the mold is heated. This is achieved by ultrasonic hot embossing
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