1. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003 UkMIG – Update and Future Work Dr Ben Whiteside IRC in Polymer Engineering Bradford February 2003 Dr Ben Whiteside IRC in Polymer Engineering Bradford February 2003

2. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003 Current Work 1 Microsystem50 process monitoring 2 Moulding Trials 3 Morphology Measurements 4 Publications 5 Going smaller 6 Future Work 1 Microsystem50 process monitoring 2 Moulding Trials 3 Morphology Measurements 4 Publications 5 Going smaller 6 Future Work

3. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003 Dynisco PCI 4011 Piezo load transducer ( 10kN) Dynisco PCI 4006 piezo load transducer (2.5kN) 1 Process Measurement - Sensor Installation Temposonics R series displacement transducer J-type thermocouples

4. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003 1 Process Measurement – Data Capture Injection Pressure Cavity Pressure Ram Displacement Ram Velocity 3 Temperature Channels Injection Pressure Cavity Pressure Ram Displacement Ram Velocity 3 Temperature Channels Max sampling rate ~ 30 000Hz

5. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003

6. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003

7. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003

8. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003 1 Process Measurement - Issues/Discussion Isolate source of oscillation Servo drive? Mechanical linkage? Intelligent monitoring Reject bad parts Process control Isolate source of oscillation Servo drive? Mechanical linkage? Intelligent monitoring Reject bad parts Process control

9. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003 2 Moulding Trials Materials moulded Dec 2002/Jan 2003: - BP Rigidex 5050 HDPE BIP POMC 109 Polyacetal co-polymer PA6 w/ 2% Carbon Nano-composite Materials moulded Dec 2002/Jan 2003: - BP Rigidex 5050 HDPE BIP POMC 109 Polyacetal co-polymer PA6 w/ 2% Carbon Nano-composite

10. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003 2 Moulding Trials Materials due for moulding Feb 2003: - PP based Nano-composite (Brunel) Hapex bone analogue material PEEK? High temperature oil heaters arrived Jan 2003 Materials due for moulding Feb 2003: - PP based Nano-composite (Brunel) Hapex bone analogue material PEEK? High temperature oil heaters arrived Jan 2003

11. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003 3 Morphology Measurements - AFM

12. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003 3 Morphology Measurements - Structure Nano-indent Crystal Structure Crystal Structure

13. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003 3 Morphology Measurements – Spherulite size

14. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003 3 Morphology Measurements – Amorphous layer

15. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003 3 Morphology Measurements - Importance Proportion and geometry/orientation of crystal structures have a very significant influence on the mechanical properties of the product Material data sheets specify mechanical property data based on tests on thick ~4mm sections Not applicable to these components Proportion and geometry/orientation of crystal structures have a very significant influence on the mechanical properties of the product Material data sheets specify mechanical property data based on tests on thick ~4mm sections Not applicable to these components How will the micromoulded component perform?

16. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003 3 Morphology Measurements - Application Influence of processing parameters upon morphology can be assessed Careful control of processing conditions may allow the moulder to tune the mechanical performance of the final product Influence of processing parameters upon morphology can be assessed Careful control of processing conditions may allow the moulder to tune the mechanical performance of the final product Proportion of amorphous material is inversely proportional to the size of product Smaller products offer more control Proportion of amorphous material is inversely proportional to the size of product Smaller products offer more control

17. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003 4 Publications Conference Papers: - Antec2003 – Nashville, USA, 2003 PPS19 – Melbourne, Australia, 2003 Journal Papers: - Plastics Rubber Composites Polymer Engineering and Science Conference Papers: - Antec2003 – Nashville, USA, 2003 PPS19 – Melbourne, Australia, 2003 Journal Papers: - Plastics Rubber Composites Polymer Engineering and Science

18. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003 5 Going smaller… Mini/Micromoulding cavities have proved useful for: Familiarisation with the micromoulding process Surface finish measurements Developing property measurement techniques Mini/Micromoulding cavities have proved useful for: Familiarisation with the micromoulding process Surface finish measurements Developing property measurement techniques But the work performed so far suggests we now need to move to smaller length scales

19. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003 5 Going smaller…

20. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003 5 Going smaller - Top Hat Moulding Disc diameter = 1mm Cylinder diameter = 0.5mm Volume = 0.34mm 2 Disc diameter = 1mm Cylinder diameter = 0.5mm Volume = 0.34mm 2 1 mm

21. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003 6 Future Work – coming months February 2003 Complete moulding trials with remaining materials Commissioning of top hat micromoulds March 2003 Complete characterisation of moulded samples Morphology measurements Nano-composite dispersion Mould/product surface detail comparisons February 2003 Complete moulding trials with remaining materials Commissioning of top hat micromoulds March 2003 Complete characterisation of moulded samples Morphology measurements Nano-composite dispersion Mould/product surface detail comparisons

22. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003 6 Future Work - onwards March Moulding of top hat cavities Product assessment Bradford/Rondol Micro-Injection Compounder experiments Bringing it all together – EPSRC final report March Moulding of top hat cavities Product assessment Bradford/Rondol Micro-Injection Compounder experiments Bringing it all together – EPSRC final report

23. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003 6 Future Work – New Bid Areas of interest: Mould manufacture – techniques, precision, detail, surface finish Modelling of the process – can accepted theories cope? Smaller length scales – build on existing infrastructure Controlling morphology Areas of interest: Mould manufacture – techniques, precision, detail, surface finish Modelling of the process – can accepted theories cope? Smaller length scales – build on existing infrastructure Controlling morphology

24. UNIVERSITY OF BRADFORD UNIVERSITY OF BRADFORD MicroMoulding 2003 Thank You