The manufacture of micro-components has always been the application of injection molding technology, however, a "magic" thermoforming process can produce high-quality micro-components. At the 16th Annual Meeting of SPE Thermoforming Technology, the micro-thermoforming process was discussed and the potential application potential of the process in the micro-electromechanical market was proposed. The technologies discussed at the same time include: “Chromium-like effect†TPO components, “four-sports station pistons†that reduce the molding cycle, and PD500Mega cylinders that can quickly change molds.
Micro Thermoforming Technology The Microstructure Technology Institute of Forschungszentrum Karlsruhe, Germany, is a large, government fund-based research organization. Researchers at the facility have developed a laboratory-scale thermoforming process that is said to be capable of forming micro-components between 0.1 and 1000 nm (1000 nm = 1 μm), meeting industry-standard microforming requirements for the first time. The process was developed to meet the needs of micro-components in the life sciences, such as disposable LOC microfluidic devices for the synthesis and analysis of biochemical reagents for pharmaceutical research.
As a microscopically improved technology, this new thermoforming system consists of three parts: a flat plate mold with a microcavity, a perforated platen for vacuum and air pressure, and a seal between the mold and the platen. facility. The process is to mount the mold on a laboratory press and then insert a piece of plastic film (20-50 μm) into the mold. After the press is closed, although the film between the mold and the platen is not compressed, a certain degree of vacuum is obtained. As the mold is completely closed, the film is compressed and heated. When the film reaches the thermal deformation temperature, it flows into the mold cavity under a pressure of about 50 bar. At this time, the mold has cooled to 20 ° C, low. The thermal deformation temperature of the material. As the air pressure drops, the mold opens and the micro-components are formed.
A three-part TPO thermoformed bumper decorated with a chrome-like decorative film was first applied to trucks. The mold used in the process can be machined, EDM, photolithographic, electroplated, wet or dry. Processing by etching, laser, etc. Metals, ceramics, glass and silicon carbon compounds can be used as mold materials. This process can use a 50 μm thick polystyrene, polycarbonate or cyclic olefin copolymer film.
The first application superior to injection molding micro-thermoforming technology is a 10 mm x 10 mm bio-culture chip with 675 pits on each chip. Previously, the chip was produced by micro-injection molding technology, and it was necessary to manually remove the material after molding. Now using micro-thermoforming technology, it is possible to manufacture parts with a thickness of several μm and a smooth surface, which is difficult to achieve by other methods.
Thermoforming technology is used in the field of manufacturing of microcomponents. The picture shows a cell culture piece produced by a new process developed by a German research institute, which is covered with micro-cavities. The limitation of micro-thermoforming technology is that it needs to be operated manually, so that the molding cycle is relatively long, generally required 10min, therefore, the current development direction of the technology is to develop automated pressure systems and molding systems, as well as advanced heating systems, to maintain the mold temperature to replace the preheating process of the film, thereby reducing the molding cycle and increasing the yield.
It is said that the research institute of micro-thermoforming technology is currently issuing its patent technology license to thermoforming processors in Europe and the United States, and the pharmaceutical packaging industry will become the first field of application of this technology.
Chromium-like TPO components In the annual competition for component products, the highest award in automotive products was awarded to a truck bumper component. The bumper member is composed of three parts, and the TPO caps at both ends have a surface effect similar to chrome, which is said to be processed by the so-called thick sheet forming technique (ThickSheetForming), that is, the decorative film is laminated on the sheet. The material is molded to form the part.
The PD500Mega cylinder from ToolingTechnology can withstand 25,000 lbs of pressure, which can change molds quickly, reducing the time from 1h to 10min
Hendrickson International, Inc., a manufacturer of truck bumpers, adheres a chromium-like film to a 0.187 in (1 in = 25.4 mm) thick TPO sheet. ThermoformerProfilePlastics uses low pressure technology to produce parts with Class A surfaces that achieve the effect of chrome steel. TPO is said to be selected because it exhibits good flexibility and impact resistance at -40 °C.
Tool information Marbach has developed a so-called "four-motion plug" for the processing of square PP containers, which is said to reduce the molding cycle by 10%. Its cam-driven "finger" extends the material to every corner, allowing for faster forming with thinner sheets. This piston made of regular foam can reduce the weight of parts by more than 20% and can be used in the production of PP platters or butter drums. The first user of this technology in Europe and Australia is Huhtamaki.
For molding manufacturers of large-size products, a PD500Mega cylinder from TechnologyLLC can quickly position and lock the mold to withstand 25,000 lbs of pressure. Its high-strength steel handles withstand high shear loads and quickly change or position the mold, which is said to reduce the replacement time from 1h to 10min.
Micro Thermoforming Technology The Microstructure Technology Institute of Forschungszentrum Karlsruhe, Germany, is a large, government fund-based research organization. Researchers at the facility have developed a laboratory-scale thermoforming process that is said to be capable of forming micro-components between 0.1 and 1000 nm (1000 nm = 1 μm), meeting industry-standard microforming requirements for the first time. The process was developed to meet the needs of micro-components in the life sciences, such as disposable LOC microfluidic devices for the synthesis and analysis of biochemical reagents for pharmaceutical research.
As a microscopically improved technology, this new thermoforming system consists of three parts: a flat plate mold with a microcavity, a perforated platen for vacuum and air pressure, and a seal between the mold and the platen. facility. The process is to mount the mold on a laboratory press and then insert a piece of plastic film (20-50 μm) into the mold. After the press is closed, although the film between the mold and the platen is not compressed, a certain degree of vacuum is obtained. As the mold is completely closed, the film is compressed and heated. When the film reaches the thermal deformation temperature, it flows into the mold cavity under a pressure of about 50 bar. At this time, the mold has cooled to 20 ° C, low. The thermal deformation temperature of the material. As the air pressure drops, the mold opens and the micro-components are formed.
A three-part TPO thermoformed bumper decorated with a chrome-like decorative film was first applied to trucks. The mold used in the process can be machined, EDM, photolithographic, electroplated, wet or dry. Processing by etching, laser, etc. Metals, ceramics, glass and silicon carbon compounds can be used as mold materials. This process can use a 50 μm thick polystyrene, polycarbonate or cyclic olefin copolymer film.
The first application superior to injection molding micro-thermoforming technology is a 10 mm x 10 mm bio-culture chip with 675 pits on each chip. Previously, the chip was produced by micro-injection molding technology, and it was necessary to manually remove the material after molding. Now using micro-thermoforming technology, it is possible to manufacture parts with a thickness of several μm and a smooth surface, which is difficult to achieve by other methods.
Thermoforming technology is used in the field of manufacturing of microcomponents. The picture shows a cell culture piece produced by a new process developed by a German research institute, which is covered with micro-cavities. The limitation of micro-thermoforming technology is that it needs to be operated manually, so that the molding cycle is relatively long, generally required 10min, therefore, the current development direction of the technology is to develop automated pressure systems and molding systems, as well as advanced heating systems, to maintain the mold temperature to replace the preheating process of the film, thereby reducing the molding cycle and increasing the yield.
It is said that the research institute of micro-thermoforming technology is currently issuing its patent technology license to thermoforming processors in Europe and the United States, and the pharmaceutical packaging industry will become the first field of application of this technology.
Chromium-like TPO components In the annual competition for component products, the highest award in automotive products was awarded to a truck bumper component. The bumper member is composed of three parts, and the TPO caps at both ends have a surface effect similar to chrome, which is said to be processed by the so-called thick sheet forming technique (ThickSheetForming), that is, the decorative film is laminated on the sheet. The material is molded to form the part.
The PD500Mega cylinder from ToolingTechnology can withstand 25,000 lbs of pressure, which can change molds quickly, reducing the time from 1h to 10min
Hendrickson International, Inc., a manufacturer of truck bumpers, adheres a chromium-like film to a 0.187 in (1 in = 25.4 mm) thick TPO sheet. ThermoformerProfilePlastics uses low pressure technology to produce parts with Class A surfaces that achieve the effect of chrome steel. TPO is said to be selected because it exhibits good flexibility and impact resistance at -40 °C.
Tool information Marbach has developed a so-called "four-motion plug" for the processing of square PP containers, which is said to reduce the molding cycle by 10%. Its cam-driven "finger" extends the material to every corner, allowing for faster forming with thinner sheets. This piston made of regular foam can reduce the weight of parts by more than 20% and can be used in the production of PP platters or butter drums. The first user of this technology in Europe and Australia is Huhtamaki.
For molding manufacturers of large-size products, a PD500Mega cylinder from TechnologyLLC can quickly position and lock the mold to withstand 25,000 lbs of pressure. Its high-strength steel handles withstand high shear loads and quickly change or position the mold, which is said to reduce the replacement time from 1h to 10min.
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