Finite element simulation of ultrasonic embossing on polymers

Tan, Jun; Lin, Wen Jong; Lam, Yee Cheong

doi:10.1109/icarcv.2014.7064491

Cited by 4 publications

(2 citation statements)

References 3 publications

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“…Comprehensive studies have been carried out to explain the underlying physics of the process, [13][14][15] and the process has been successfully applied to the manufacturing of microfluidic channels, [13][14][15][16] optical diffusers, 17 and even circuit boards. 18,19 Several other studies have investigated the effect of the process parameters on replication quality.…”

Section: Introductionmentioning

confidence: 99%

Utilization of cross‐correlation function for assessment of replication quality in ultrasonic embossing of microchannels on polymethyl methacrylate

Yildirim,

Ulku,

Arikan

2024

Polymer Engineering & Sci

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Ultrasonic embossing—a process where a horn vibrating at 20–30 kHz compresses on a thermoplastic substrate sitting on a mold to replicate the features on the mold to the substrate—is a promising method for fabricating microchannels on thermoplastics due to reduced cycle time and relatively low equipment cost. Replication quality in ultrasonic embossing has been investigated in the literature by primarily referring to the replication depth. However, this approach does not fully reflect the fidelity between the mold and the replicated feature, especially at the side walls, which are typically designed to be vertical in microchannels. We propose using cross‐correlation—a method that quantifies the similarity between two signals by measuring the overlap of their patterns—between the derivative of the mold profile and the embossed profile as a figure of merit that accurately reflects the fidelity of the side wall. For testing purposes, we embossed straight microchannels on polymethyl methacrylate (PMMA) using micron‐scaled protrusions on a brass mold fabricated by CNC milling. The mold comprised 100, 300, and 1000‐μm‐wide protrusions of same designed height of 300 μm, resulting in aspect ratios (AR) of 3, 1, and 1/3, respectively. Cross‐correlations between the derivatives of the profiles ranged between 0.50 and 1.00, while cross‐correlations between the profiles were greater than 0.97 in all cases, showing the sensitivity imposed by utilizing the derivatives. Setting average of all cross‐correlation values (0.8) as the quality threshold, we observed that high AR (3) features were replicated at low quality, while low AR (1/3) features were replicated at high quality, regardless of the process parameters. In replicating unit AR features, the process parameters were observed to affect the quality, where the combination of vibration time and pressure was the most significant compared to individual effects of the parameters.Highlights Parameters' effect on replication of varied aspect ratio features was assessed. Assessment was carried out by cross‐correlating mold and channel profiles. Cross‐correlating derivatives of profiles provide a more sensitive means. General rules for replication quality in ultrasonic embossing were driven.

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Section: Introductionmentioning

confidence: 99%

Utilization of cross‐correlation function for assessment of replication quality in ultrasonic embossing of microchannels on polymethyl methacrylate

Yildirim,

Ulku,

Arikan

2024

Polymer Engineering & Sci

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“…Comprehensive studies have been carried out to explain the underlying physics of the process [7][8][9], and the process has been successfully applied to the manufacturing of micro uidic channels [7,10], optical diffusers [11], and even circuit boards [12,13].…”

Section: Introductionmentioning

confidence: 99%

Utilization of Cross-Correlation Function for Assessment of Replication Quality in Ultrasonic Embossing of Microchannels on Polymethyl Methacrylate (PMMA)

Yildirim,

Ulku,

Arikan

2023

Preprint

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Ultrasonic embossing is a promising method for fabricating microchannels on thermoplastics due to reduced cycle time and relatively low equipment cost. Replication quality in ultrasonic embossing has been investigated in the literature by primarily referring to the replication depth. However, this approach does not fully reflect the fidelity between the mold and the replicated feature, especially at the side walls, which are typically designed as vertical in microchannels. We propose to utilize cross-correlation between the gradients of the mold profile and the embossed profile as a figure of merit sensitive to the side wall’s fidelity. For testing purposes, we embossed straight microchannels on polymethyl methacrylate (PMMA) using a brass mold comprising 100, 300, and 1000 µm-wide protrusions of same designed height of 300 µm, resulting in aspect ratios (AR) of 3, 1, and 1/3, respectively. Cross-correlations between the gradients of the pofiles ranged between 0.50 and 1.00, while cross-correlations between the profiles were greater than 0.97 in all cases, showing the sensitivity imposed by utilizing the gradients. Setting average of all cross-correlation values (0.8) as the quality threshold, we observed that high AR (3) features were replicated at low quality, while low AR (1/3) features were replicated at high quality, regardless of the process parameters. In replicating unit AR features, the process parameters were observed to affect the quality, where the combination of vibration time and pressure was the most significant compared to individual effects of the parameters.

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Low-cost and fast fabrication of the ultrasonic embossing on polyethylene terephthalate (PET) films using laser processed molds

et al. 2017

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Finite element simulation of ultrasonic embossing on polymers

Cited by 4 publications

References 3 publications

Utilization of cross‐correlation function for assessment of replication quality in ultrasonic embossing of microchannels on polymethyl methacrylate

Utilization of cross‐correlation function for assessment of replication quality in ultrasonic embossing of microchannels on polymethyl methacrylate

Utilization of Cross-Correlation Function for Assessment of Replication Quality in Ultrasonic Embossing of Microchannels on Polymethyl Methacrylate (PMMA)

Low-cost and fast fabrication of the ultrasonic embossing on polyethylene terephthalate (PET) films using laser processed molds

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