Micro-nanostructured polymer surfaces using injection molding: A review

• Published in: Materials today communications 2017-12, Vol.13, p.126-143
• Main Authors: Maghsoudi, K., Jafari, R., Momen, G., Farzaneh, M.
• Format: Article
• Language: English
• Subjects: Demolding; Injection molding; Micro-nanostructure; Processing parameters; Replication
• ISSN: 2352-4928; 2352-4928
• DOI: 10.1016/j.mtcomm.2017.09.013

[Display omitted] •A review on different aspects of injection molding of micro-nanostructured polymer surfaces including insert-making, processing, and demolding.•Some less studied areas such as micro injection molding of rubber materials are covered and the importance of chemical antistiction coatings is highlighted.•The effects and opportunities of various insert materials, particularly the polymeric and hybrid inserts are assessed.•Mold temperature, injection velocity, and holding pressure are the most important parameters affecting the replication quality of the final product.•As the effects of the main parameters are not consistent across variable processing conditions, finding the best-matched condition is crucial. Micro injection molding is in great demand due to its efficiency and applicability for industry. Polymer surfaces having micro-nanostructures can be produced using injection molding. However, it is not as straightforward as scaling-up of conventional injection molding. The paper is organized based on three main technical areas: mold inserts, processing parameters, and demolding. An accurate set of processing parameters is required to achieve precise micro injection molding. This review provides a comparative description of the influence of processing parameters on the quality of final parts and the precision of final product dimensions in both thermoplastic polymers and rubber materials. It also highlights the key parameters to attain a high quality micro-nanostructured polymer and addresses the contradictory effects of these parameters on the final result. Moreover, since the produced part should be properly demolded to possess a high quality textured polymer, various demolding techniques are assessed in this review as well.