Nano-structured mould tools for plastics

Plastic components are often produced with injection moulding, an established low-cost and high-throughput method. For nano- and micro-scale surface patterning, a variety of chemical techniques are often employed. With EU support of the project PLAST4FUTURE, scientists are developing a nanoimprint lithography-based method for structuring the free-form surfaces of injection moulding tools and tool inserts.

Nanoimprint lithography is a procedure to form patterns by mechanical deformation. By using moulds and moulding tools with structured surfaces, the manufacturing process is greatly simplified. Further, minimising contamination of raw material with additives such as pigments improves recyclability and significantly reduces energy consumption associated with raw material production. PLAST4FUTURE industrial partners are leaders in their respective fields. Three highly advanced demonstrators in automotive, lighting and functional toy colouring applications are planned to showcase the technology.

During the first reporting period the team developed detailed technical specifications for the demonstrators. In addition, scientists have defined all parts needed to make the demonstrators. The complete process flow for nanoimprint lithography-structuring of moulding tools and tool inserts will ensure that the tools can make the demonstrators.

In the meantime, researchers developed a new steel for the tools that is optimised for nano-structuring. A novel surface polishing process has been integrated into the milling machine for automated robotic polishing. The robotic arm has an integrated optical tool to measure surface roughness during processing. All parts of the PLAST4FUTURE production chain from cradle to grave have been evaluated for environmental impact via a life-cycle assessment.

The technology will add a Fourier transform infrared (FTIR) fingerprint so that batches can be identified with FTIR spectroscopy for cases such as product recall. The team began benchmarking activities associated with the demonstrators, developing new injection moulding tools and inserts to create novel structures that modify light propagation.

PLAST4FUTURE aims to provide a manufacturing chain to produce high-value plastic products with functional surfaces by low-cost injection moulding. The technology will greatly simplify the production of nano-structured plastic components for a variety of industries and will secure for the EU a large share of a growing global market.