Laser-micromachining of 3D injection molds to fabricate easy-flow polymeric containers

点击翻译按钮获取中文摘要

A frequent problem in the use of food and waste packaging is the final emptying of containers. Food decomposition emissions are a major contributor to global warming, acidification and enthrophication. Thus, there is an interesting environmental gain in completely emptying food packaging. Of similar importance is sustainable waste packaging and easy emptying of waste containers. Non-stick, self-emptying containers would be a welcome innovation. In this CRD project, three academic researchers in Canada and Germany have joint forces with a globally acting bulk and food packaging manufacturer (IPL Inc.) and an injection mold fabricant (Moulexpert) to develop an industrial process for the fabrication of easy-flow and self-cleaning plastic containers. We propose to (1) fundamentally assess the relationship between polymer flow into micro and nanotextures by rheological studies, (2) establish a femtosecond laser machining protocol for fabricating textured mold surfaces suitable for molding and de-molding of container side walls in an effort to induce the desired easy-flow self-cleaning functionality onto the resulting polymer part, (3) assess lubricant-infusion in the textured polymer surfaces for the fabrication of robust slippery self-healing container insides, (4) take laser-micromachining of metallic mold surfaces from the laboratory scale to the industrial level with establishing appropriate parameters for high-throughput laser machining and finally (5) texture a complex industrial injection mold for the fabrication of food or waste containers. The outcomes have direct value for the industrial partners as they can therewith extend their product range and revolutionize the packaging sector. One PDF, one PhD and two UG summer students will be trained in the context of this project. They will gain valuable insights not only in the fundamental research fields of polymer rheology, laser-matter interactions and surface wetting but also with respect to application when running industrial injection molding tests at IPL Inc. The results from this research work will have a direct effect on the life of Canadians, as less food wasted and easier compost handling will overall reduce landfill waste and protect the environment from further emissions. Furthermore, Canada will stand out as a nation bringing forward a revolutionary technology that could be applied to other industries based on injection molded parts as well.