PLAST4FUTURE

Injection Moulding Production Technology for Multi-functional Nano-structured Plastic Components enabled by NanoImprint Lithography

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 Obiettivo del progetto (Objective)

'Micro- and nanometer structuring has proven to be an efficient method to functionalize surfaces, and is attractive to manufacturers of plastic products. Plastic components are volume manufactured by injection moulding. Compact Discs and Digital Video Discs are today manufactured with nanometer range lateral resolution but, only on planar surfaces. Free-form (double-curved) moulding tools today offer resolutions down to 100 μm, limited by the methods used for creating the injection moulding tools. The objective of the project is to upgrade existing injection moulding production technology for manufacture of plastic components by enhancing the lateral resolution on free-form surfaces down to micro- and nanometer length scales. This will be achieved through the development of a complete nanoimprint lithography solution for structuring the free-form surface of injection moulding tools and tool inserts. This will enable a cost effective and flexible nanoscale manufacturing process that can easily be integrated with conventional mass production lines. The proposed technology enables functionality of plastic surfaces by topography instead of chemistry. This will significantly simplify the introduction of new products to the market, safer to produce and use. The proposed technology allows production of plastic surfaces with several different functionalities using the same material. This simplifies recycling and supports a cradle-to-cradle production philosophy. The proposed technology will be developed to meet specific industry demands from partners representing the plastic industry including the automotive, lighting and toy industries. During the project the European Trade Organisation representing the European plastic industry will disseminate the PLAST4FUTURE technology towards inter-sectoral end-users. An OEM service, provided by participating SMEs and Large Enterprises, will be established to secure a lasting value supporting European competitive strength.'

Introduzione (Teaser)

Plastics form the backbone of components in numerous industries including automotive, lighting and toy manufacturing. New moulds and mould tools that imprint nano-structured patterns directly during plastic processing will enable major improvements in production.

Descrizione progetto (Article)

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 http://www.plast4future.eu/ (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.