研究目的
To develop an injection mold for LSR injection molding swiftly and effectively using rapid tooling (RT) technology, and to investigate the feasibility of injection molding using the fabricated injection mold.
研究成果
The study successfully developed an injection mold for LSR injection molding using RT technology. The fabricated mold showed high replication and transcription rates, and the variations in dimension of the LSR molded parts could be controlled within ± 1 μm. The average surface roughness of the mold was only slightly increased after 200 test runs, indicating its potential for precision optical components production.
研究不足
The replication and transcription rates cannot be achieved 100% due to the shrinkages of the silicone rubber and Al-filled epoxy resins used in the fabrication of the LSR injection mold.
1：Experimental Design and Method Selection:
The study used RT technology to develop an injection mold with a heating element for LSR injection molding. The replication and transcription rates of the mold and molded parts were investigated.
2：Sample Selection and Data Sources:
The master model of the Fresnel lens was used to fabricate the LSR injection mold. Dimensions of the microstructures were measured using an optical microscope (OM) and a white-light interferometer (WLI).
3：List of Experimental Equipment and Materials:
Equipment included a common horizontal LSR molding equipment (Allrounder 370S 700-290, ARBURG), mix and metering system (SilcoStar 902B, 2KM Inc.), and LSR (LR 3003/50 A/B, Wacker Elastosil Inc.). Materials included aluminum-filled epoxy resins (TE-375, Jasdi Chemicals Inc.) and room-temperature vulcanizing (RTV) elastomers.
4：Experimental Procedures and Operational Workflow:
The process involved fabricating the LSR injection mold using RT technology, performing LSR injection molding, and measuring the dimensions and surface roughness of the molded parts.
5：Data Analysis Methods:
The dimensions of the microstructures were measured using an OM, and the surface roughness was examined using a WLI. The replication and transcription rates were calculated based on these measurements.
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7502
7502
Chroma Inc.
White-light interferometer (WLI) used to examine the surface roughness of the plastic injection parts.
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Allrounder 370S 700-290
370S 700-290
ARBURG
Common horizontal LSR molding equipment used for manufacturing LSR parts.
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SilcoStar 902B
902B
2KM Inc.
Mix and metering system used in preparing the materials for LSR injection molding.
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LR 3003/50 A/B
3003/50 A/B
Wacker Elastosil Inc.
LSR material used in the study, delivered at a rate of 1:1 from 20-L pail.
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TE-375
375
Jasdi Chemicals Inc.
Aluminum-filled epoxy resins used to fabricate an injection mold for LSR injection molding.
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KE-1310ST
1310ST
Shin Etsu Inc.
Component A of RTV elastomers used to make the intermediary molds.
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CAT-1310
1310
Shin Etsu Inc.
Component B of RTV elastomers used to make the intermediary molds.
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F-600
600
Feiling, Inc.
Vacuum machine used to eliminate trapped air bubbles resulting from the mixing process under vacuum conditions.
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DH400
400
Deng Yag Inc.
Oven used to cure the fabricated injection mold to obtain the required mechanical properties for LSR injection molding.
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AP-030
030
SAGE Inc.
Air-cooled chiller used to supply cold water to jacketed fittings of the injection machine barrels for delaying the curing process before the LSR introduction to the mold.
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M835
835
Microtech Inc.
Optical microscope (OM) used to measure the dimensions of the microstructures of the Al-filled epoxy resin mold and LSR molded parts.
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