Task 4.1

Process Characterisation.

(P. Bolt - M. Heckele)

The replication process mapping will be expanded to all 4M partners. To be able to compare hot embossing and injection moulding, some criteria will be agreed before performing comparitive studies. Based on the questionnaire established during the first stage of the 4M project, qualitative and quantitative comparison studies of replication processes for hot embossed and injection moulded microstructures will be conducted and the results used to formulate design for manufacture rules for polymer micro components. To carry out this process characterisation, polymer microstructures with typical functional features employed in different applications will be selected. Experiments on these microstructures will be conducted in parallel by partners to verify the process limitations when MIs produced employing alternative toolmaking technologies and moulding materials are used. An overview of Nanoimprint process will be delivered to identify potential complementary with micro-processing replication. Qualitative and quantitative comparison studies will be delivered.
Based on this potential complementarity, hybrid processing will be proposed to process polymers with a higher added value for end use applications. A working group will be formed to study the evolution and the status of the roll to roll process. As a mass production process, this mid term potential technology is supposed to be the future low cost polymer foil processing for sensors, electronic organic or photovoltaic applications. Firstly, this task will focus on identifying gaps in the existing R2R manufacturing process, to identify the main advantages and to propose a roadmap based on existing marketing studies. A knowledge data base of R2R process will be delivered. In a second step a comparison with current replication processes (µ-injection, hot embossing) will be performed. To be able to evaluate and compare with current replication processes, some criteria will be agreed. New manufacturing routes will be proposed by the partners who are already involved in such technologies (TNO, CEA, FhG, IMTEK).