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Replicative manufacturing of metal moulds for low surface roughness polymer replication

Kluck, Sebastian; Hambitzer, Leonhard; Luitz, Manuel; Mader, Markus; Sanjaya, Mario; Balster, Andreas; Milich, Marcel 1; Greiner, Christian ORCID iD icon 1; Kotz-Helmer, Frederik ; Rapp, Bastian E.
1 Institut für Angewandte Materialien – Computational Materials Science (IAM-CMS), Karlsruher Institut für Technologie (KIT)

Abstract:

Tool based manufacturing processes like injection moulding allow fast and high-quality mass-market production, but for optical polymer components the production of the necessary tools is time-consuming and expensive. In this paper a process to fabricate metal-inserts for tool based manufacturing with smooth surfaces via a casting and replication process from fused silica templates is presented. Bronze, brass and cobalt-chromium could be successfully replicated from shaped fused silica replications achieving a surface roughnesses of Rq 8 nm and microstructures in the range of 5 µm. Injection moulding was successfully performed, using a commercially available injection moulding system, with thousands of replicas generated from the same tool. In addition, three-dimensional bodies in metal could be realised with 3D-Printing of fused silica casting moulds. This work thus represents an approach to high-quality moulding tools via a scalable facile and cost-effective route surpassing the currently employed cost-, labour- and equipment-intensive machining techniques.


Verlagsausgabe §
DOI: 10.5445/IR/1000150637
Veröffentlicht am 04.10.2022
Originalveröffentlichung
DOI: 10.1038/s41467-022-32767-2
Scopus
Zitationen: 7
Web of Science
Zitationen: 6
Dimensions
Zitationen: 8
Cover der Publikation
Zugehörige Institution(en) am KIT Institut für Angewandte Materialien – Computational Materials Science (IAM-CMS)
Publikationstyp Zeitschriftenaufsatz
Publikationsjahr 2022
Sprache Englisch
Identifikator ISSN: 2041-1723
KITopen-ID: 1000150637
HGF-Programm 43.34.02 (POF IV, LK 01) Hybrid and Functionalized Structures
Erschienen in Nature Communications
Verlag Nature Research
Band 13
Heft 1
Seiten Art.-Nr.: 5048
Vorab online veröffentlicht am 27.08.2022
Nachgewiesen in Dimensions
Scopus
Web of Science
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