08:30 - 09:00
09:00 - 09:10
Michael Døssing, TOOLpartners A/S
G. Tosello, DTU Mechanical Engineering
Part 1 - Nano Plast Project
09:10 - 09:20
NanoPlast project: surface micro- and nano-structuring
The Nanoplast project develops technologies to micro- and nanostructure the surfaces of injection molding tools and methods to injection mold plastic parts with functional nanosurfaces. Depending on the nanostructure, the plastic part can obtain surface effects such as self-cleaning, anti-reflection or color properties. This can be used to integrate a functional surface of a product directly in the molding process without using new chemistry or additional process steps. The applications are numerous – from anti-stiction coatings to color decorations.
The Nanoplast project is a collaboration between 11 Danish partners and is funded by the Danish National Advanced Technology Foundation (Højteknologifonden in Danish). The project links the unique injection molding competences of the Danish plastic industry to the public funded state-of-the-art nanotechnology infrastructure and know-how at the Danish Technical University (DTU).
Alicia Johansson is the Project Manager of the Nanoplast project (together with Associate professor Rafael Taboryski). Alicia has a PhD in micro- and nanotechnology from DTU-Nanotech.
09:20 - 09:45
Tools manufacturing for pilot productions
In the NanoPlast project NIL Technology has demonstrated how to use a technique usually used in the semiconductor industry for the manufacturing of injection moulding tools. This technique – called Nano Imprint Lithography, NIL – is capable of making nano structuring into steel, and this has made it possible to demonstrate how an optical grating can be made directly onto a polymer surface. This will result in optical effects similar to those known from holograms made into polymer foils – often seen on credit cards, computers soft ware boxes, and other items where OEM guarentees are important. The traditional method – known as embossing – can only be used on polymer foils that has to be made as a separate seal before it is glued to a plastic part. By the use of NIL we are offering a new possiblity to the injection moulding industry for making unique surface properties on a polymer. The technique is also allowing nano structures to be made onto double curved surfaces and recent examples of this completely new possibility for the injection moulding industry is shown.
Brian Bilenberg Olesen, CTO and founder of NIL Technology
09:45 - 10:10
Inmold – method for polishing of injection molding tools (Nanoplast project)
Henrik Pranov, Inmold
Inmold Biosystems is a classic university spin-out from Risø-DTU, which develops technologies for surface modification of plastic. Inmold started out by developing a method to attach proteins on plastic surfaces during the injection molding process. This method, however, had some requirements to the surface chemistry and the roughness of the injection molding tools that could not be achieved by conventional technology and it has been necessary for Inmold to develop methods to address these issues. During the last few years, three methods have been the main focus for Inmold and especially polishing of injection molding tools have been of great interest for the injection molding industry.
In the talk, the methods developed by Inmold will be presented.
Henrik Pranov, has been CSO/CEO and founder af Inmold Biosystems since the start-up in 2007. Henrik has a degree in Chemical Engineering/Applied Physics from DTU and has written a PhD on injection molding of nanostructures at Risø-DTU.
10:10 - 10:40
Part 2 - Nano Plast Project (2)
10:40 - 11:05
Nano plast presentation 3
Nano structure at injection moulded surfaces will increase the value of the moulded plastic product. At this speech you will hear about product opportunities with micro/nano features at the surfaces of the plastic product. In near future commercial structures, such as structure with self-cleaning properties, hydrophobicity, structural colors or other optical properties will be at the market and these structures will be integrated in new products. We can see the development at the “lab–on–chip” products and point of care products are moving forward at the marked, but most with micro structures. The Medical industry is implementing this new technology very fast.
The NanoPlast project and the sister project Plast4Future have focus at injection moulded structures in nano scale and will open the market for using the technology, so it will be used in the toy, food and automotive industry in the future.
Michael Døssing has founded TOOLpartners® in 2007 and has been the Managing Director since the start-up. Michael has been working in the plast- and tool business his entire work life and knows the importance of both the detail and the overview while focusing determined for results.
11:05 - 11:30
Injection molded self-cleaning surfaces
Since the discovery of the origin to the super hydrophobic surface of the lotus leaf there has been a large increase in research trying to replicate the extraordinary properties of the lotus leaf. In most cases super hydrophobic surfaces also leads to self-cleaning surfaces, meaning that drops that roll off the surface will carry any dirt in the surface with it. It is widely accepted that the super hydrophobic properties of the lotus leaf originates from the surface chemistry combined with a surface structure both on the micro- and nanometre scale. In this system the surface structures enhance the chemical properties of the surface, making hydrophobic wax into a super hydrophobic surface. The artificial replication of the super hydrophobic effect is past the proof of concept phase and have been realised through various low throughput methods. These methods often involve overhanging structures that cannot be realised by moulding, or materials with very high contact angle that cannot be achieved without the use of fluorinated polymers. At DTU Nanotech the ongoing research focus on achieving the super hydrophobic effect with the material and geometrical constraints forced by injection moulding. Micro and nanostructured moulds are fabricated using modern clean room techniques at DANCHIP, e.g. Deep-UV stepper and D-RIE etching. A positive silicon master can with high fidelity be inverted to a mould by electroplating with Nickel. Using the nickel mould as an insert in a tool it is possible to replicate the structures from the silicon master into polymer by injection moulding.
Nis Korsgaard Andersen: BSc and MSc in engineering from Technical University of Denmark in the field of Physics and Nanotechnology. PhD student since October 2012, with the thesis entitled “Fabrication of nanostructured polymer surfaces and characterization of their wetting properties”. The project is supervised by Rafael Taboryski and Fridolin Okkels and founded by DTU Nanotech.
Part 3 - PolyNano project
11:30 - 11:55
Tooling and injection moulding for surface nano structuring
Patterning large areas with micro-to-nanostructured geometries yields different surfaces functionality. The need for practical low-cost and high volume production for both distributed and deterministic nano geometries has shifted attention toward polymer replication as injection moulding.
Distributed nano-semi-sphere pattern over a large area of 30x80 mm2 and a series of deterministic nanostructures such as nanochannels on a 100 mm diameter template were fabricated.
The deterministic geometries were fabricated on a 100 mm diameter silicon wafer. The channels defined by e-beam were etched by selective reactive ion etching. The nickel stamper used for injection moulding was fabricated by subsequent nickel electroplating. Injection moulding process optimization in terms of melt temperature, mould temperature, packing time and pressure, was performed. Transferring with high accuracy nano geometries fabricated on the nickel master into the polymer substrate is a key aspect. The capability of the injection moulding process by means of optimized parameters to replicate the produced deterministic and distributed geometries in the thermoplastic Cyclic Olefin Copolymer (COC) Topas 6013 was studied.
Replication quality assessment was performed using atomic force microscopy comparing critical dimensions in the nickel stampers with corresponding polymer nano-features dimensions.
Matteo Calaon obtained his BSc Engineering degree in Italy at the University of Padua in 2007 and his MSc in Manufacturing Engineering and Management at the Technical University of Denmark (DTU) in 2009. In 2010 Matteo started working as research assistant at the Section for Manufacturing Engineering of the Department of Mechanical Engineering (DTU) on projects related to polymer micro-nano systems.
Since August 1st 2011 he has been working as a PhD Student in Micro and Nano Manufacturing at the Technical University of Denmark, Department of Mechanical Engineering (MEK). The overall objective of the PhD project is to develop methods and approaches to process chain validation for the fabrication of Lab-on-a-Chip devices aimed at high volume mass production.
11:55 - 13:00
Part 4 - Hi-Micro project (1)
13:00 - 13:10
Hi-Micro project: High precision production technologies for
high quality 3D micro-parts
The Hi-Micro project intends to realise an innovative approach for the design, manufacturing and quality control of tool inserts to achieve significant breakthrough in mass production of precision 3D micro-parts, through further developing both enabling manufacturing technologies, including additive manufacturing (AM), micro electrical discharge machining (micro-EDM), micro electro-chemical machining (micro-ECM) and micro-milling, and unique metrology and quality control methods such as computer-tomography (CT) metrology and digital holography.
Together with industrial technology providers, the Hi-Micro project will further bolster the performance of industrial equipment for mass production of precision 3D micro-parts, through modular design of tool insert units with improved thermal management capability, development of on-machine handling system and in-line quality control device. Activities will run over the entire value chain of mass production of precision 3D micro-parts, from product and tool insert design, manufacturing of tool inserts, micro injection moulding processes, to the production equipment and quality control in the whole production chain.
The Hi-Micro project is funded by the European Commission under the 7th Framework Programme, has a duration of 3 years (2012-2015), has a budget of 5.2 M€ (39MDKK) and involves 11 partners from 5 EU countries (Germany, Belgium, Denmark, United Kingdom and The Nederland).
Guido Tosello is associate professor on polymer micro/nano processing at the Department of Mechanical Engineering of the Technical University of Denmark, where he received his PhD title "Precision Moulding of Polymer Micro Components" in 2008. Guido holds an MSc in Mechanical Engineering from the University of Padova (Italy) and he has 8 years of experience of research on precision engineering, micro technology, polymer micro processing, micro/nano metrology. He is member of the Polymer Processing Division of Multi-Material Micro Manufacturing Network of Excellence 4M, member of the NanoMicro Moulding Special Interest Group of SPE (Society of Plastic Engineers), member of Euspen (European Society for Precision Engineering and Nanotechnology), member of the Polymer Group of ATV-SEMAPP, and associate member of CIRP (The International Academy for Production Engineering). He is author and co-author of more than 80 peer-reviewed international publications including journal articles, conference papers, and book chapters.
13:10 - 13:35
Micro and ultra precision machining for micro injection moulding applications
Small plastic parts nowadays can be found in numerous applications ranging from consumer electronics to high performance measurement devices. For a high volume production of these parts, appropriate replication processes like micro injection moulding are utilized. The machining of the required moulds is of particular importance for the success of these processes. Depending on the shape and quality requirements of moulds, either micro or ultra precision machining is applied for their manufacture.
This presentation will introduce relevant machining processes from the fields of precision and diamond machining for the generation of micro injection moulds and present latest results from research in this field.
Precision milling allows a flexible machining of a wide range of geometries with high material removal rates. Even in hardened tool steels, superior surface finish, fine topography features and defined structures or geometrical elements can be achieved. Recently, this process has been used to machine specimens for testing the mechanical behaviour of micro injection moulded polymer parts and to develop novel products for biomedical applications.
Diamond machining comprises various machining processes, like turning, milling or planning, which are able to machine moulds in optical quality. Depending on the applied process kinematics, several types of mould geometries, including freeform and structured surfaces, can be generated.
Lars Schönemann is scientific research assistant at the Laboratory for Precision Machining (LFM) at the University of Bremen. He has a Master’s degree in Systems Engineering focusing on machine oriented programming and embedded systems from the University of Bremen. After his graduation in 2008, he joined the LFM where his current work focuses on microstructuring processes for the generation of prismatic micro optics (Diamond Micro Chiselling).
13:35 - 14:00
Advancements on the simulation of the micro injection moulding process
Maximilian Marhöfer, DTU Mechanical Engineering
Process simulations are applied in micro injection moulding with the same purpose as in conventional injection moulding: optimization and support of the design of mould, inserts, parts, and process. Commercial software is however not well suited for micro injection moulding. The software is developed for macro plastic parts and it is therefore limited in the capability of modelling the polymer flow in micro cavities properly. Nonetheless, current developments of the simulation technology brought up new opportunities for improved accuracy. In this speech, new strategies and aspects for comprehensive simulation models which provide more precise results for micro injection moulding are discussed. Modelling and meshing recommendations are presented, leading to a multi-scale mesh of all relevant process and system units of micro injection moulding. The implementation and influence of process boundary conditions (e.g. venting, machine behaviour) on simulations results are described. Ultimately, the importance of cooling simulations settings is addressed.
Maximilian Marhöfer is currently doing his PhD studies at the Technical University of Denmark (DTU), Department of Mechanical Engineering (DTU MEK). The project is titled “Design and Manufacture of Micro Products Using Concurrent Engineering” with research focus on micro injection moulding.
Maximilian obtained his BSc diploma in Micro Systems Engineering at the University of Freiburg, Germany, in 2009 where he focused on micro technology and micro manufacturing. During his exchange stay at DTU and his internship at Sonion, Roskilde, Denmark, in 2010, he worked mainly on plastics technology and micro injection moulding. He continued his studies at the University of Freiburg (Germany) where he graduated with MSc diploma in Micro Systems Engineering in 2012.
His main interests are in the fields of micro fabrication, in particular in polymer and plastics technology, micro injection moulding and simulations of the injection moulding process. In accordance to these fields, he is a member of the European Society for Precision Engineering and Nanotechnology (euspen).
14:00 - 14:30
Part 5 - Hi-Micro project (2)
14:30 - 14:55
High precision 2K-Micro Injection moulding with formicaPlast with integrated automation systems
Björn Dormann, DESMA
Based on the new machine concept of a two-component micro – injection machine (2C-µIMM) a flexible and compact example of supply chain for the production micro parts were developed. The process chain contains the technologies of high precision micro injection moulding technology
Because of the difficult contact with miniaturised components not only technological and machine-technical adaptations, but also the following treatment steps must already be considered with the micro injection moulding production . Micro injection moulding parts have connected a low weight with a surface relatively big to the mass. Beside the originating adhesive-static the electric-static forces often lead to the liability of the parts in the tool surfaces, what prevents sure dropping into the container. Against dropping, the damage or pollution speaks with micro injection moulding parts in many cases also of sensitive functional surfaces. A manual use of the parts is, because of the low dimensions (the parts are not partially surely recognizable with bare eyes) and because of the delicacy of the surfaces no more possible. With the micro injection moulding process, the application of using automation devices can be necessary already with unusually low numbers of micro parts.
Bjoern Dormann is Manager of the Technology Department of Kloeckner DESMA Schuhmaschinen GmbH. Bjoern Dormann has experience in development, applications, and service of machines and production systems for the footwear industry as well as for the technical applications from DESMA. He joined DESMA in 1990, undertaking vocational training as an industrial electrician. He worked for more than 2 years in the service department and has experience in the installation of the DESMA machines world-wide. He worked for 2 years in the application department for development of robot systems as new technologies for the footwear industry. Also during this time he gained experience in the soling materials: thermoplastics, polyurethane and rubber. Since 2003 he has been manager of the technology department. He graduated with a Bachelor’s degree in engineering in 2000 and afterwards in computer science in 2001 in Bremen / Germany.
Part 6 - Micro product and process development
14:55 - 15:20
The culture of micro engineering at Ortofon Microtech:
1 Company and 2 brands
Ortofon is a world leading specialist and developer of professional audio products: acclaimed phono cartridges, headshells, tonearms, high-end audio cables, step-up transformers and head phones.
In Ortofon Microtech we use our competences in the field of precision engineering for our B2B Costumers, in the hearing aid and medical device industry. Ortofon specializes in the development and manufacturing of micro precision TPE and rubber components, from ideas to final product.
Our focus is on new developing in acoustics, materials, micro assembly and micro moulding.
The importance of having a world-wide network of suppliers and technology partners.
Ortofon has recently joined with DTU Mekanik on the new FP7 EU project HINMICO (“High throughput integrated technologies for multimaterial functional Micro Components").
René Elsborg is Factory Manager at Ortofon A/S since 2006.
Head of micro production technologies, responsible for in and out sourcing of technologies, overall responsible of technical project management, responsible for getting new technologies applied to the organization by partners and networking.
René Elsborg has for more that 20 year been working with technical management, precision engineering and R&D, among other as: Technical manager at Codan Medical, Head of R&D and technical department, development and production of medical devices; and Technical Manager for West Pharmaceutical Services, development in Drug Mixing/Administration Systems and Components. Material science pharmaceutical rubber grades, vulcanization and advanced cutting, punching and assembly techniques.
15:20 - 15:45
Polymer micro fluidic and micro optics applications
Morten Olesen, ACTURA NanoTech ApS
Compression injection moulding of micro and nanostrutured polymers combined with printed electronics, laser welding, coatings, inspection and assembly under mass manufactoring conditions. These are some of the commercial technologies and competences Actura Nanotech offer clients today.
Products with features such as micro optics, micro fluidics, cell growth topologies and sensors are typically very difficult to produce in high volume in a production environment. To ensure the requested quality standards met regardless of producing thousands or millions pieces of a critical component, Actura Nanotech have established a rich supply chain ranging from consulting, engineering, mastering, moulding, assembly, print and packaging to international sales and warehousing.
As a contract mass manufacturer we aim to support a successful transformation of clients proven demonstrators to matured competitive products ready for mass market. The speech will describe the challenge to handle this type of projects and how we use rapid prototyping and best practice engineering as some of our tools to get success with our business.
Morten Olesen is an entrepreneur working with innovation, bussiness development and strategic design specialiced in the use of microfuntional solutions. Morten is founder of the company Actura Nanotech offering prototyping and mass production of micro and nano structured polymers for optics, sensors, topologies for cell growth as well as printed electronics.
15:45 - 16:00
Exchange and discussion / Review of specific points/Evaluation