Manufacturing of micro-structured parts for mass production purposes

Micro-structured and thus functionalized surfaces offer high potentials for new approaches in processing techniques and product design. However, for mass production purposes quite a few challenges regarding the manufacturing of these surfaces have to be overcome. For the fast and economic production of large quantities of structured polymer films the extrusion embossing process is suitable. For embossing microstructures there are special requirements on temperature control because of the double function of the embossing roll. On the one hand the roll is used as an embossing roll with a high surface temperature to improve the embossing accuracy. On the other hand it is used as a cooling roll with a low surface temperature. Only by using variothermal heating systems these contradictory demands on the temperature control can be met. In order to achieve a high quality of the produced micro-structured films an integrative analysis and optimization of the entire process chain is required. This includes the manufacturing of suitable embossing rolls, the development of coating systems and the adaption of the extrusion process. This paper deals with the entire process chain for functionalized, super hydrophobic plastic parts with contact angles up to 165°. Therefore, conelike surface structures, mimicking the structure of lotus leaves, are replicated. Functionalized parts are produced in the injection molding as well as in the extrusion process; however, this paper focuses on the process chain of the extrusion process.