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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - ProSurf (High Precision Process Chains for the Mass Production of Functional Structured Surfaces)

Teaser

Summary

The ProSurf project aims to enhance the surface functionalities of six demonstrator parts by using a wide range of high precision manufacturing technologies, such as diamond machining techniques, enabling the mass production of cost effective, structured parts with accurate replication technologies, like micro injection moulding. By implementing these technologies to manufacture a variety of benefiting functionalities, it is critical to assess the parts quality in a safe and fast manner. Therefore, the ProSurf project incorporates the development of robust in-process metrology as well as the derivation of the surfacesâ€™ functions to three dimensional parameters for a fast measurement of functional relevant surface characteristics and specific function testing of the produced demonstrators. Due to the spectrum of surface functionalities linked to the part demonstrators and their varied application fields that range from optical to medical, ProSurf enables to reach a high impact on several areas of the society by, e.g. increasing the safety of medical procedures and the performance of moulds for ceramic injection moulding as well as cleaning rolls for electronic parts.

Work performed

A kick-off meeting was organized in the second week after the ProSurf project start in January 2018 in order to bring all partners together, explain and agree on commons tools and practices and officially initiate the work of ProSurf. Thereafter, the technical work initially concentrated on specifying the six demonstrators. First, their functionalities were defined along with measurable values to quantify if the expected outcome has been achieved or even exceeded. Then, whenever possible, the respective functionalities have been described by physical models that relate the functionality of the demonstrator to the respective geometric features. Concurrently, the definition of the demonstrator parts and process chains were finalized. The outcome at the end of M12 was a complete set of specification of the six demonstrators, including part layouts, envisioned functionalities, geometry of the structured surfaces and possible process chains for their production.
Along with the definition of the demonstrators, each partner has started working extensively on making their respective technological field, e.g. the mould machining, moulding process or the applied metrology, capable of producing the ProSurf demonstrators.
The main results achieved thus far are:

ProSafety - Surgical lens with holograms for anti-counterfeit and batch tracking
- The optical design was adapted by UBRE and its linked third party BIAS to consider refractive optics instead of reflective.
- The capability of the nFTS machining process to structure freeform surfaces has been demonstrated by IWT.
- A geometrical model, describing the engagement conditions of the diamond tool and the freeform surface, has been developed for the nFTS process.
- First nanostructures have been replicated onto ophthalmic lenses by POX
- An optical test stand for functional characterisation has been devised by UBRE

ProClean - Substrate contact cleaner
- The surface properties of various contact cleaners have been analysed by TEKNEK to obtain a better understanding of the relation between surface structure and cleaning performance
- Test samples of structured surfaces were sent to TEKNEK by all partners to assess their cleaning capability

ProMatte - Multifibre Optical Connector with anti-reflective surfaces
- Two strategies for replicating anti-reflective structures on microlenses and the have been proposed and are currently evaluated: 1) having both the lenses and the anti-reflective pattern on a flexible stamp and using this to generate the final mould or 2) applying the anti-reflective structure to a flexible stamp and using it on a pre-machined mould containing the microlenses
- The microlenses for the ProMatte insert have been manufactured using micro electrical discharge machining (Î¼EDM).
- A first nanoimprinted ProMatte insert is ready for injection moulding.

ProFlow - Ceramic high-temperature sensor cap
- Mould cavity surface can be structured by micro-EDM for the ProFlow demonstrator.
- Preliminary CIM activities to produce ProFlow have been performed at FORMATEC.
- KUL and FORMATEC are currently investigating a new mould insert made of niobium carbide.

ProPatt - Transparent hydrophobic micro-patterned surface
- PolyU has presented two novel diamond machining processes, modulated diamond cutting (MDC) and virtual spindle based tool servo (VSTS) diamond turning, both addressing specific challenges in machining structured surfaces.

ProDeco - Surfaces with decorative effects for polymer consumer products
- Several machined topographies of the metal structure were investigated by NILT (polishing, milling, EDM, grinding, etc.). The aim is to identify which topographies are suitable for nanopatterning by imprinting.
- Tool inserts with diffractive structures were utilized by DTU to assess the replication fidelity in injection moulding.

Results applicable for multiple demonstrators
- A general scheme framework for data processing when doing geometrical characterisations has bee

Final results

The state of the art has been significantly advanced in the respective fields of each partner and further progress is being expected until the end of the project. At the end of the project, the capabilities for mass producing functional structured surfaces will be showcased using the demonstrators developed in ProSurf, which each focus on a different type of functionality. Along with the exhibition of fully functional test parts, all steps of the required process chains will be described in a way that industrial partners are able to further devise commercial product from this.