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级成型技术所需的科学基础。在生物工程、医学、微电子和光学应用中，具有极小临界特性的聚合物基组件越来越受到重视。对于此类部件的大批量生产，精密微/纳米注射成型具有很大的前景。目前的项目包括紧密耦合的过程建模和科学基础开发所需的实验努力，从而使这种制造成为可能。该项目的主要目标是全面开发和验证适用于微纳米注射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、壁边界条件和材料流变假设，这些假设只适用于常规的大规模注射成型。目前的模型开发工作是通过微/纳米尺度成型特定假设的基本理论原理的定制应用来消除这些限制。理论发展的过程是按顺序进行的，以隔离所涉及的复杂性。在整个研究过程中，理论发展得到加强，并通过紧密耦合的微成型流程可视化实验进行了依次验证。除了作为对提出的新边界条件和材料特性模型进行微调的一种手段外，该实验还可以通过微/纳米级模塑来探索产品制造的能力。其中包括最重要的重点倡议，以确保该方案具有广泛的科学和教育影响。在专业一级，通过与项目工业咨询委员会的密切合作，正在促进技术转让。在国家研究方面，通过新成立的微/纳米级模塑研究焦点小组，正在促进最佳和协作的美国科学基础发展，该小组每年召开一次会议，分享想法和合作机会。最后，在当地社会层面，该项目的一个特别之处在于，通过与理哈伊大学工程专业的学生一起进行基于微/纳米成型的团队产品开发项目，每年让40名有动力的、主要是少数民族的中学生和高中生享受到在知识边界动手工程的乐趣，从而提高未来工程劳动力的多样性。

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.