Fabrication of a Large-Area, Fused Polymer Micromold Based on Electric-Field-Driven (EFD) μ-3D Printing
Fabrication of a Large-Area, Fused Polymer Micromold Based on Electric-Field-Driven (EFD) μ-3D Printing
复制标题
基于电场驱动 (EFD) mu-3D 打印的大面积熔融聚合物微模具的制造
DOI：
10.3390/polym11111902
复制
发表时间：
2019-11-01
期刊：
影响因子：
5
通讯作者：
Lan, Hongbo
中科院分区：
文献类型：
--
作者：
Peng, Zilong;Gou, Nairui;Lan, Hongbo
一种电场驱动（EFD）、mu-3D打印、熔融聚合物技术已经被开发出来，用于使用典型的聚合物材料制造大面积微型原型模具，包括微晶蜡（MC-wax）、聚己内酯（PCL）和聚甲基丙烯酸酯（PMMA）。本文提出了一种大面积微尺度模式的替代方案，克服了传统模具制造行业高成本的局限性。EFD原理使熔融聚合物材料的打印比喷嘴直径小一个数量级以上，有助于Taylor锥射流的颈缩效应，这是实现微尺度制造的关键因素。通过对三种聚合物半月板和衬底之间的电场分布进行数值模拟，阐明了在可打印电压下电场分布对三种聚合物半月板状态的依赖关系，确定了EFD mu-3D打印的电场参数。许多实验成功地打印了大范围的粘度材料，范围从数万mpa到数十万mpa的PCL和PMMA。研究了不同材料的粘度、拉伸性能和表面能等参数的差异，以评估其在不同领域的应用。在适当的工艺参数和内径为200 μ m的喷嘴下，完成了3个不同的应用案例，包括最小点直径为20 μ m的Wax芯片和微通道、最小线宽为5 μ m的PCL网状结构和最大纵横比为0.8的PMMA大面积模具。结果表明，EFD mu-3D打印具有打印分辨率高、聚合物材料通用性强等突出优点。
An electric-field-driven (EFD), mu-3D printed, fused polymer technique has been developed for the fabrication of large-area microscale prototype molds using typical polymer materials, including microcrystalline wax (MC-wax), polycaprolactone (PCL), and polymathic methacrylate (PMMA). This work proposes an alternative for large area microscale modes and overcomes the limitation of high cost in the traditional mold manufacturing industry. The EFD principle enables printing of fused polymers materials more than one order of magnitude lower than the nozzle diameter, contributing to the necking effect of the Taylor cone jet, which is the key factor to achieve the microscale manufacturing. Numerical simulation of electric field distribution between the meniscus and substrate was carried out to elucidate the dependence of electric field distribution on the meniscus condition of three types of polymers under printable voltage, and the electrical field parameters for the EFD mu-3D printing were determined. A number of experiments were printed successfully using a large range of viscosity materials, ranging from tens of mPas to hundreds of thousands of mPas of PCL and PMMA. The differences in parameters of different materials, such as viscosity, tensile properties, and surface energy, were studied to assess their use in different fields. Using proper process parameters and a nozzle with an inner diameter of 200 mu m, three different application cases were completed, including a Wax microarray and microchannel with a minimum dot diameter of 20 mu m, a PCL mesh structure with a minimum line width of 5 mu m, and a PMMA large-area mold with a maximum aspect ratio of 0.8. Results show that the EFD mu-3D printing has the outstanding advantages of high printing resolution and polymer material universality.