Algorithm for Micro‐Profiling from Image of the Injection Molds Complex Surfaces

Abstract

Nature is an excellent source of inspiration. Understanding nature can lead to new discoveries of new materials, applications, products. Scientists have found out technologies that seek to mimic some of life's unique innovations. In Germany researchers have developed a synthetic shark skin made of elastic silicone that reduces bio-fouling. Engineers from the Massachusetts Institute of Technology have developed some "biomimicry" material out of glass and plastic that collects minute amounts of water, just like the Namib Desert beetle's back. Polymer composites are used for a very good replication of the mold cavities surface microstructures. Transformation of image to surface could be an economical solution for machining the injection mold cavities for mimic the inspiration source. In this paper an algorithm for combining the tool paths obtained on an image-to-surface technique with the tool paths on a complex shaped cavity is presented. The algorithm is tested by micro-milling an injection mold surface of a cavity for a scale model stone wall and the injection molding experiments have proven the high quality of detail replication.