Search

The industrial interest in the patterning of polymeric surfaces at the micro/nanoscale to include new functionalities has considerably increased during the last years. Hierarchical organization of micro/nanometric surface textures yields enhanced functional properties such as hydrophobicity, hydrophilicity, antibacterial activity, and optical or chromatic effects to cite some. While high accuracy methods to pattern hierarchical surfaces at the nanoscale have been developed, only some of them have been applied for high volume manufacturing with limited success, mainly because they rely on the use of expensive machinery and moulds or complicated inserts. Therefore, a method using low cost recyclable tooling and process conditions applicable to high-volume manufacturing is currently missing. In this work, a scalable and low-cost method to replicate hierarchical micro/nanostructured surfaces on plastic films is presented, which can be latter used as inlays for injection moulded parts with standard processing conditions. This method is used to demonstrate the feasibility of replicating three level hierarchical micro/nano textured surfaces using recyclable bio-based polymers (of high relevancy in the current plastic pollution context) achieving replication ratios above 90%, comparing the replication results with those obtained in polypropylene. The presence of the micro/nanotextures substantially increases the contact angle of all the polymers tested, yielding values higher than 90° in all the cases. Also, various mechanical properties of the replicated parts for all the polymers injected are characterized one and thirty days after the samples were manufactured, showing fairly constant values. This highlights the validity of the replicated surfaces, regardless of the biopolymers special crystallization characteristics.

Micro- and nanotexturization of surfaces can give to the parts different advanced functionalities, such as superhydrophobicity, self-cleaning, or antibacterial capabilities. These advanced properties in combination with the biocompatibility of Liquid Silicone Rubber are an interesting approach for obtaining high-performance medical devices. The industrial production of surface textures in polymeric materials is through the replication technique, and the best option to attain a high production rate is injection molding. Moreover, its low viscosity during processing can provide an accurate replication capacity by the easy filling by capillarity of the microtextures. An innovative replicating technique for Liquid Silicone Rubber is presented by studying the replication of different shaped textures within a diameter range of between 2 and 50 µm. The copying process consists in the overmolding of a textured polymeric inlay obtained by nanoimprint lithography. At the end of the process, a textured part is obtained, while the imprinted film remains in the mold. The injection molding parameters are optimized to increase the replication accuracy, and their effect on texture replicability is analyzed and discussed. Finally, it is shown that the textured surfaces improve their wettability behavior, which is a necessary and important characteristic in the development of biomedical devices.

Many papers have been written describing the use of ray tracing techniques inside glasses with inhomogeneous refraction index. This paper considers the different aspects that have to be explored to in order to establish the feasibility of the manufacturing of a progressive addition lenses (PAL) using Gradient Index materials (GRIN).