Laser-micromachining of molds to fabricate easy-flow polymeric surfaces

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IPL Inc., founded in 1939 in Québéc, is a leading North American manufacturer of injection-molded plastic products including thin-wall overcaps and containers. Two major markets for IPL are food packaging and organic waste composting containers. Both types of containers are subject to problems related to their contents sticking to the walls, such as food being wasted and bad odors arising due to fouling. With this collaborative project we plan to proof that non-stick, self-emptying containers can be produced through molding the polymer with a laser-micromachined steel mold. Imparting a microstructure through laser-machining onto metals is a well understood method developed in Prof. Kietzig's lab. By using a laser-structured metal mold to form plastics, we expect to imprint the inverse pattern onto the polymer surface. By careful design of the surface structure, self-cleaning and self-emptying properties are expected to result on the polymer product. We will laser machine five different surface structures on steel substrates, which will subsequently be used to mold two different polymer resins. We will assess the surface quality of the mold and the polymer products by microscopy techniques and perform contact angle measurements to assess the self-cleaning behavior. Thus this project will enable IPL Inc to make an informed investment decision for its endeavour to revolutionize the bulk packaging market with easy-flow containers. Aside from the competitive advantage gained by IPL through this novel technique, the implementation of such surfaces will considerably reduce additional container handling steps, wasting remaining product in containers and thus contribute to a greener Canada.