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Embossing is an important design and functionality element. For instance, embossing is used to apply braille letters on medical products, or to enhance folding packages or brochures due to haptic effects. Usually, a multilayered cardboard material is used for such types of products. Up to now, high-quality and functional embossing has so far been associated with an extraordinarily large amount of experience-based know-how and with many cost-intense trial-and-error experiments due to the mechanical complexity of cardboard material. In the presented work it is shown how experimental investigations and numerical simulations based on Finite-Element-Analysis can contribute to a virtual prediction of the embossing process and, therefore, can help to reduce time-consuming and expensive experiments.

Embossing is a commonly used design element on printed products and packaging. It enhances the product impression with optical and haptic effects. The material deformation during the embossing of cardboard is normally done using high mechanical pressure between two dies. The use of ultrasound in the embossing process leads to a noticeable reduction of the embossing pressure and a greater embossing precision. However, there is a noticeable heating of the cardboard during the ultrasonic-assisted embossing process. This work aimed to characterise the effects of heating and to understand the reasons for the greater precision with decreased force when ultrasound is used. Therefore, the effects of the thermal ultrasonic energy on the chemical composition and the morphological properties of the fibres were investigated. The findings showed that no noticeable changes occurred in the chemical composition or fibre geometry as a result of the embossing process with ultrasound.

During the embossing process, a fiber sandwich is compressed between embossing tools. The use of ultrasound causes a short-term increase in the material temperature in addition to causing plastic deformation. The combination of the material compression and an increase in material temperature leads to structural changes, which can be observed by the change in mechanical properties of the cardboard. This work investigated the influence of an ultrasonically induced temperature increase on the structural changes of cardboard. Using three-parameter combinations, different temperature levels were achieved with a material densification of less than 5%. Subsequently, the samples were subjected to selected physical and visual analyses to characterize the change in the fiber structure. With the increase of 124 ºC material temperature there was a decrease of about 15% in the splitting resistance and 10% in the bending stiffness.

Liquid sessile drops can be used as sacrificial templates for the creation of pores in polymeric microsieves. Using inkjet printing, we deposit sessile drops of a water-based liquid onto a hydrophobic solid support and cover them with a thin liquid layer of a polymer solution in such a way that the sessile drops penetrate through the top interface of this layer. The liquid layer is solidified, and the sessile drops imprint their shape into it, acting as templates for the creation of pores. Finally, the polymer layer is separated from the substrate, and a freely suspended polymer microsieve is obtained.

Micro- and nanostructures exhibit a growing commercial interest where a fast, cost-effective, and large-area production is attainable. Laser methods have a great potential for the easy fabrication of surface structures into flexible polymer foils like polyimide (PI). In this study two different concepts for the structuring of polymer foils using a KrF excimer laser were tested and compared: the laser-induced ablation and the laser-induced shock wave structuring. The direct front side laser irradiation of these polymers allows the fabrication of different surface structures. For example: The low laser fluence treatment of PI results in nano-sized cone structures where the cone density can be controlled by the laser parameters. This allows inter alia the laser fabrication of microscopic QR code and high-resolution grey-tone images. Furthermore, the laser treatment of the front side of the polymer foil allows the rear side structuring due to a laserinduced shock wave. The resultant surface structures were analysed by optical and scanning electron microscopy (SEM) as well as white light interferometry (WLI).

First results of experiments on the surface characterization of cellulose derivatives are presented. Different water contents of the surface of microcrystalline cellulose have been investigated by means of Raman spectroscopy, SERS, and environmental scanning electron microscopy (ESEM).

A method for analysis of carbon-containing thin films by using surface enhanced Raman spectroscopy (SERS) is described. Thin films of boron nitride or silicon carbide which are deposited on carbon filaments were coated additionally with silver nanoparticles. A very thin plasma polymer film was deposited on the silver particles to give a better long time stability. Using these layers, very intensive carbon band were detected.