Sequential combination of micro-milling and laser structuring for manufacturing of complex micro-fluidic structures

Abstract

This paper deals with the combination of micro milling and laser micro structuring for processing hot embossing dies for microfluidic applications. This strategy permits the advantages of each process technology to be exploited in order to achieve a cost and time efficient process and also to process forms and structures which cannot be manufactured with the single processes micro milling and laser micro structuring. Basic requirements are a high-precision positioning of the single process areas and also a good machining of the parts and structures with the manufacturing processes micro milling and laser micro structuring. The intersections between the different processing areas present a challenge for this process technology

Complex Micro Machining of an Injection Mold Surface for a Conductive Polymeric Composite Product

“…On a portal type machine tool for combined processes equipped with a revolving head supporting two milling spindles, one measuring system and one laser ablation scanner was produced a 62 HRC tool steel microfluidic mold insert of 4 mm by 5 mm and a depth of 0.7 mm first by milling on NC paths generated from 3D part model. Then, it was deburred by laser ablation for which the paths were generated by following procedure : acquiring the geometry from the milled cavity (due to huge amount of data it was used a different computer) , generating surfaces and then the export of the STL type file to the laser controller, were, the STL file is divided into the slices of a thickness corresponding to the material removal of one scanner path with constant machine tool axis z-position (in the range of 100 nm for finishing and a few micrometres for roughing, depending on material and laser parameters), then, the slices were hatched with a constant step (10 µm-20 µm) [13].…”

“…During experiments it was evidenced the influence of the feeds to the stability of the system and there were analysed smooth profiles in order to reduce the acceleration / deceleration which could introduce vibrations. Schubert et al [9,13], Sugar et al [10] or Uhlmann and Essmann [14] presented a laser ablation method in which the laser beam paths are calculated on vectors extracted from hatched slices of the part to be machined and the laser beam movements controlled by the scanner with the optical mirrors system. In contrast, on the technology presented in Table 3 only the laser beam is generated in continuous mode with the scanner as a circle of 0.03 mm diameter hatched with a step of 0.01 mm and the laser beam movements are calculated as paths on a parallel strategy with steps of 0.02 to 0.03 mm at 45º controlled by the VMC's SELCA 3045P ( fig.…”

Novel Manufacturing Route for Scale Up Production of Terahertz Technology Devices

“…For example, a combination of micro-milling and laser structuring was reported to produce complex biotechnology products with feature sizes smaller than the cutting tool diameter without compromising machining time. This manufacturing platform benefits from the complementary capabilities of its constituent technologies for a higher removal rates and higher machining resolution, respectively [7]. However, an important limitation of current hybrid manufacturing platforms is that they are product specific, which makes their fabrication capabilities highly dependent on products' specific technical requirements and also vulnerable to design changes even within their respective application areas [6].…”

Generic integration tools for reconfigurable laser micromachining systems

“…Furthermore, another direction in broadening the capabilities of the laser micro machining technology is its integration in hybrid manufacturing platforms [12]. For example, an integration of micro-milling and laser structuring was reported to produce complex biotechnology products with feature sizes smaller than the cutting tool diameter without compromising machining time [13].…”