Optimization of hot embossing molding process parameters of Fresnel lens using Taguchi method

Kuo, Chil-Chyuan; Chen, B.-C.

doi:10.1002/mawe.201500443

Cited by 5 publications

(3 citation statements)

References 18 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Further investigation is necessary to equip with conformal cooling channels [15 -17] in a large-area hot embossing mold for shortening cycle time during hot embossing molding. In addition, optimization of hot embossing molding process parameters using Taguchi method is in progress [18].…”

Section: Resultsmentioning

confidence: 99%

A Simple Method for Rapid Manufacturing Large-area Hot Embossing Rapid Toolings and its Application

Kuo

Wu²

2018

View full text Add to dashboard Cite

Hot embossing process has been frequently used in the microfabrication. Developing a low-cost and simple manufacturing method to fabricate a large-area embossing mold is an important issue. The purpose of this study was to propose a cost-effective method for rapid fabricating large-area hot embossing molds with aluminum (Al)-filled epoxy resins. The 1 : 0.75 is the optimal mixture ratio for mixing epoxy resin and recycled Al-filled epoxy resin powders and the optimal thickness for a large-area hot embossing mold is 15 mm. The total manufacturing cost savings about 52.4 % and the last process manufacturing cost savings about 61.6 % can be obtained using the method proposed in this work. A large-area hot embossing mold has smooth mold surfaces and can be carried out in about 3 days. The fabricated largearea hot embossing mold is rigid enough for short runs of parts using hot embossing molding.

show abstract

Section: Resultsmentioning

confidence: 99%

A Simple Method for Rapid Manufacturing Large-area Hot Embossing Rapid Toolings and its Application

Kuo

Wu²

2018

View full text Add to dashboard Cite

show abstract

“…If the practical embossing temperature is not sufficiently high to soften the polymer substrate, the polymer cannot fully fill in the cavities of the microstructured mold. Previous studies have demonstrated that the practical embossing temperature and embossing pressure are the two most critical processing parameters in the traditional hot embossing process [16,17]. Thus, the optimal molding area of the proposed process can be defined by controlling the two key processing parameters.…”

Section: Processing Conditions and Output Quality Of The Novel Multil...mentioning

confidence: 99%

Novel multilayered hot embossing process for fabricating a microstructure pattern on various polymer substrates

Chang¹,

Tsao²,

Wang³

2020

J. Micromech. Microeng.

View full text Add to dashboard Cite

This paper describes a novel, multilayered hot embossing method for fabricating a microstructure pattern on various polymer substrates. The method involves a multilayered hot embossing process with three polymer substrates (polycarbonate, polymethyl methacrylate, and low-density polyethylene), three pieces of microstructured molds, and graphene-based heaters. Only one hot embossing step is required in which a microstructure pattern is directly fabricated onto the three polymer substrates. The total processing cycle time is less than that of the traditional hot embossing process. In this study, thin graphene-based heaters were fabricated and tested. A facility that integrates graphene-based heating and multilayered hot embossing was designed and implemented. Under the proper processing conditions, a hemispherical microlens array and a microcylinder array pattern were successfully fabricated on the three polymer substrates. Finally, the uniformity of embossing temperature and the replication quality of the microstructure patterns were measured and analyzed. The technique shows great potential for the rapid and flexible fabrication of microstructure patterns on various polymer substrates.

show abstract

“…To date, many studies have experimentally and numerically investigated the deformation and flow behavior of thermoplastic polymer during hot embossing [ 23 , 24 , 25 , 26 ]. The replicated pattern quality of the hot embossed part is significantly influenced by the process parameters, such as embossing pressure, embossing temperature, and holding time [ 27 , 28 , 29 , 30 , 31 ]. Furthermore, the effects of the geometric structures and size of the mold cavity on the hot embossing process are critical issues that need to be addressed, because the polymer replication ratio and filling height of the hot embossed product share a complicated nonlinear relationship with cavity size and density [ 32 , 33 , 34 , 35 ].…”

Section: Introductionmentioning

confidence: 99%

Nonuniform Heating Method for Hot Embossing of Polymers with Multiscale Microstructures

Chang¹

2021

Polymers

View full text Add to dashboard Cite

The hot embossing of polymers is one of the most popular methods for replicating high-precision structures on thermoplastic polymer substrates at the micro-/nanoscale. However, the fabrication of hybrid multiscale microstructures by using the traditional isothermal hot embossing process is challenging. Therefore, in this study, we propose a novel nonuniform heating method for the hot embossing of polymers with multiscale microstructures. In this method, a thin graphene-based heater with a nonuniform heating function, a facility that integrates the graphene-based heater and gas-assisted hot embossing, and a roll of thermoplastic film are employed. Under appropriate process conditions, multiscale polymer microstructure patterns are fabricated through a single-step hot embossing process. The quality of the multiscale microstructure patterns replicated is uniform and high. The technique has great potential for the rapid and flexible fabrication of multiscale microstructure patterns on polymer substrates.

show abstract

Optimization of hot embossing molding process parameters of Fresnel lens using Taguchi method

Cited by 5 publications

References 18 publications

A Simple Method for Rapid Manufacturing Large-area Hot Embossing Rapid Toolings and its Application

A Simple Method for Rapid Manufacturing Large-area Hot Embossing Rapid Toolings and its Application

Novel multilayered hot embossing process for fabricating a microstructure pattern on various polymer substrates

Nonuniform Heating Method for Hot Embossing of Polymers with Multiscale Microstructures

Contact Info

Product

Resources

About