Replication of micro and sub-micro structures by means of hot embossed polymer inserts

Hot embossing enables accurate replication of polymer structures in a broad variety of polymers even in the range of micro- and nanometer. Comparatively long cycle times and high insert costs however limit the further distribution of hot embossed parts. The use of hot embossed polymer inserts for subsequent replication can improve the through-put of replicated parts and reduces the costs for fabricating several metal inserts. Investigation of material combinations for replication of micro-structured parts by hot embossed interstage inserts showed the suitability for a wide range of polymers. The stability of embossed polymer inserts for tens of replications has been proved. This technology showed a big advantage of using hot embossed polymer inserts for low volume production of micro- and nano-structured polymer parts.