The Development of Polymer Molding Science for Micro- and NanoScale Applications

目前的研究项目侧重于发展超精密微纳米成型技术所需的科学基础。 具有极小关键特征的聚合物基组件越来越多地被考虑用于生物工程、医疗、微电子和光学应用。对于此类组件的大批量生产，精密微/纳米级注塑成型具有很大的前景。 目前的项目包括密切耦合的过程建模和实验工作所需的科学基础的发展，将使这种制造。 该项目的主要目标是全面开发和验证适用于微纳米注塑成型的三维过程建模科学。迄今为止，大多数外部研究都是基于二维流动分析概念、壁面边界条件和材料流变学假设，这些假设仅适用于传统的大型注塑成型。 目前的模型开发工作是通过定制应用的基本理论原理与微/纳米模塑特定的假设，消除这些限制。 理论发展的过程是按顺序进行的，以分离所涉及的复杂性。 在整个研究过程中，理论的发展得到了加强，并通过紧密耦合的微成型流动过程可视化实验进行了验证。 除了作为微调拟议的新边界条件和材料属性模型的手段外，该实验还可以通过微/纳米级成型探索产品制造的能力。 其中包括一些重点突出的举措，以确保该计划产生广泛的科学和教育影响。 在专业一级，正在通过与项目工业咨询委员会的密切合作促进技术转让。 在国家研究方面，通过新成立的微/纳米级成型研究重点小组，每年举行会议，分享想法和合作机会，促进了美国科学基础的最佳和协作发展。 最后，在当地社会层面，该计划的一个特点是通过每年让40名积极主动且大多数是少数民族的初中和高中学生在知识的边界上享受动手工程，以增强未来工程劳动力的多样性，通过与Lehigh工程学生的微/纳米成型团队产品开发项目。

The current research project focuses on the development of the science-base necessary for advancement of ultra-precision micro- and nanoscale molding technology. Polymer based components with extremely small critical features are increasingly being considered for bioengineering, medical, microelectronics, and optical applications. For the high-volume production of such components, precision micro/nanoscale injection molding holds great promise. The present project includes closely coupled process modeling and experimental efforts needed for the science-base development that would enable such manufacturing. The primary objective of the project is the comprehensive development and validation of the three-dimensional process modeling science applicable to micro and nanoscale injection molding. Most external research to-date has been based on two-dimensional flow analysis concepts, wall boundary conditions, and material rheology assumptions that are only applicable to conventional larger scale injection molding. The current model development effort is removing these limitations through the customized application of fundamental theoretical principles with micro/nanoscale molding specific assumptions. The process of theoretical development is being conducted in a sequential fashion to isolate the complexities involved. Throughout the study the theoretical development is being enhanced and sequentially verified through closely coupled micromolding flow process visualization experiments. In addition to serving as a means for the fine-tuning of proposed new boundary conditions and material property models, the experimentation is also enabling an exploration of the capabilities of product manufacture via micro/nanoscale molding. Focused initiatives of paramount importance are being included to assure the broad scientific and educational impact of the program. At the professional level technology transfer is being fostered through close collaboration with a project industrial advisory board. On the national research front, optimal and collaborative U.S. science-base development is being promoted through a newly created micro/nanoscale molding research focus group that meets annually to share ideas and collaboration opportunities. Lastly, at the local societal level, a special feature of the program is targeting enhanced engineering workforce diversity in the future by exposing 40 motivated and mostly minority middle and high school students each year to the enjoyment of hands-on engineering at the boundaries of knowledge through micro/nanomolding based team product development projects with Lehigh engineering students.