micromachines

Article
Fabrication of Micro-Structured Polymer by Micro
Injection Molding Based on Precise Micro-Ground
Mold Core
Yanjun Lu 1 , Fumin Chen 1 , Xiaoyu Wu 1 , Chaolan Zhou 1, *, Yan Lou 1 and Liejun Li 2, *
1 Guangdong Provincial Key Laboratory of Micro/Nano Optomechatronics
Engineering, College of Mechatronics and Control Engineering, Shenzhen University, Shenzhen 518060,
China; luyanjun@szu.edu.cn (Y.L.); 2172291706@email.szu.edu.cn (F.C.); wuxy@szu.edu.cn (X.W.);
susanlou121@163.com (Y.L.)
2 School of Mechanical and Automotive Engineering, South China University of Technology,
Guangzhou 510640, China
* Correspondence: zhouchaolan@szu.edu.cn (C.Z.); liliejun@scut.edu.cn (L.L.); Tel.: +86-755-86950053 (C.Z.);
+86-20-87114655 (L.L.)




Received: 18 March 2019; Accepted: 15 April 2019; Published: 16 April 2019


Abstract: Precise micro-grinding machining was proposed to fabricate regular and controllable
micro-grooved array structures on the surface of mold cores to realize the mass production and
manufacturing of micro-structured polymer components by micro injection molding in this paper.
First, the 3D topographies and section profiles of micro-ground mold cores and micro-formed
polymers with different micro-structure parameters were presented. Then, the surface roughness of
mold cores and polymers were compared. Next, the relationships between machining accuracy of
mold core ground by micro-grinding and filling rates of micro-structured polymer formed by micro
injection molding were investigated. Finally, the influences of micro injection molding parameters on
the filling rate of micro-structures polymer were investigated. It is shown that the micro-structured
polymer can be effectively and rapidly fabricated using the proposed method. The experimental
results indicate the highest form accuracy of the micro-grooved mold core and the filling rate of
micro-structured polymer can reach to 4.05 µm and 99.30%, respectively. It is found that the filling
rate of the micro-structured polymer roughly increased with increasing machining accuracy of the
mold core. The injection pressure had the greatest influence on the filling rate of the injection formed
polymer, while the melt temperature had the least influence.

Keywords: micro-grinding; micro-structure; micro injection molding; filling rate; polymer

1. Introduction
Micro-structured polymer components have been widely used in many fields, such as
optics, biomedicine, electron and microelectro-mechanical systems (MEMS), etc. [1–3]. At present,
micro-forming technologies of micro-structured polymer mainly include micro injection molding, micro
hot embossing molding, and injection compression molding, and so on [4,5]. It had been confirmed
that the micro injection molding was an alternative to the mass production and manufacturing of
micro-structured polymer products due to its short molding cycle, high efficiency, and low production
cost [6,7]. For instance, the superhydrophobic polymer surfaces with hierarchical micro-nano cylinder
array structures were successfully fabricated by micro injection molding [8]. It was shown that the
contact angle of the droplet on the hierarchical micro-nano structured polymer surface reached about
163◦ , resulting in the self-cleaning characteristic. An amorphous polymer surface with high aspect
ratio micro-structures had been fabricated by micro injection molding for application in bio-MEMS for

Micromachines 2019, 10, 253; doi:10.3390/mi10040253 www.mdpi.com/journal/micromachines

Micromachines 2019, 10, 253 2 of 15

erythrocytes depletion [9]. It had been verified that the mold temperature had the largest influence on
the replication degree of micro-features against other main process parameters. The micro injection
molding was employed to manufacture a micro-pillared polymer surface by replicating the micro
features from the mold insert with micro-cavity structures [10]. The experimental results showed that
small cavity thickness and high molding temperature had a positive effect on the replicated height
of micro-features.
However, it is very difficult to realize high form accuracy machining and manufacturing of
micro-nano structures on the surface of mold core, which directly determined the micro-forming
quality of micro-structured polymer products. For micro-nano scale machining of the micro-structured
mold core surfaces, there were many advanced processing technologies, such as chemical etching [11],
laser processing [12], electrical discharge machining (EDM) [13], fluid jet-array parallel machining
(FJAPM) [14], etc. Although chemical etching and laser processing technologies can fabricate
micro-textured structures at the nanoscale, they were very difficult to use to ensure the 3D form
accuracy of micro-structures at the micron scale. In spite of the fact that the electrical discharge
machining (EDM) could efficiently fabricate complicated 3D micro-structures, it was very difficult to
reach the smooth micro-structured surface with. The fluid jet-array parallel machining (FJAPM) may
machine smooth micro-structured surfaces, but it needed to take a lot of processing time. It was found
that a dressed super-abrasive diamond grinding wheel may perform precision micro-grinding for
mold core to obtain smooth micro-structured surface [15–17]. In order to achieve high form accuracy
and surface quality of micro-structures at the micron scale, the efficient and precise micro-grinding
technology was proposed to fabricate micro-grooved array structures with controllable form accuracy
on the surfaces of the mold core in this work. Moreover, the operation process of micro-grinding
machining was very simple, and the manufacturing cost was relatively low.
In this paper, the regular and controlled micro-grooved array structures on the surface of mold
core were machined by micro-grinding machining using a trued V-tip diamond grinding wheel. The
micro injection molding technology was employed to rapidly fabricate micro-structured polymer
parts by replicating the micro-features of mold core surface. The surface topographies and V-groove
profiles of micro-structured mold cores and polymers were presented to analyze the form accuracy of
micro-grinding and filling rate of micro injection molding. The surface roughness of micro-ground
mold cores and micro-formed polymers were compared. The relationships between the form accuracy
of micro-ground mold core and filling rates of micro-structured polymers were also revealed. The
influences of micro injection molding parameters on the filling rate of micro-structures polymer were
also analyzed.

2. Materials and Methods

2.1. Micro-Grinding of Mold Core with V-Grooved Array Structures

Compared with the traditional mold core materials, Titanium silicon carbide (Ti3 SiC2 ) exhibited
both metal and ceramic properties, including excellent machinability, good electrical conductivity, high
wear resistance, and good self-lubrication, etc. [18,19]. In this experiment, Ti3 SiC2 ceramic was chosen
as mold core material due to its good lubrication and demolding performances.
Figure 1 shows the micro-grinding machining scheme and photo of Ti3 SiC2 mold core surface with
V-grooved array structures through a computer numerical control (CNC) precision grinding machine.
First, a V-shaped tip of diamond grinding wheel was trued through mechanical V-tip mutual truing
technology along CNC interpolation trajectory [20]. Then, the Ti3 SiC2 ceramic mold core was mounted
on the horizontal work table of the grinding machine. The trued V-tip diamond grinding wheel was
driven to grind the Ti3 SiC2 mold core through numerical control system (see Figure 1a). The V-groove
was gradually formed on the surface of Ti3 SiC2 mold core through replicating the V-tip shape of the
diamond grinding wheel. When a V-groove was completed, the diamond grinding wheel was moved
at a setting space along the Z-axis direction to perform the grinding machining of second V-groove.
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Finally, the micro-grooved array structures were obtained on the surface of mold core according to
on
thethe surface
setting of moldpath.
machining coreTheaccording to the
machining setting
photo machining
of the mold corepath.
was The
shownmachining
in Figurephoto of the
1b. Because
mold core was shown in Figure 1b. Because the Ti SiC belongs to the ceramic material,
the Ti3 SiC2 belongs to the ceramic material, according to previous machining experiences, the detail
3 2 according to
previous machining
micro-grinding experiences,
conditions the detail
of mold core micro-grinding
using V-tip conditions
diamond grinding wheelof were
moldchosen
core using V-tip
and shown
diamond
in Table 1.grinding
Under thewheel
same were chosenconditions,
grinding and shown the indesigned
Table 1. Under
six setsthe same grinding
of V-grooved conditions,
structures were
the designed
ground on thesix sets ofof V-grooved
surfaces mold cores.structures wereV-grooved
The designed ground on the surfaces
parameters of mold
included cores.angle
V-groove The
α, V-groove
designed V-grooved
depth h parameters
and V-groove included
space bV-groove
which were angle α, V-groove
shown in Tabledepth h and
2. The V-groove space
corresponding moldb
which were shown in Table 2. The corresponding mold cores with different V-grooved
cores with different V-grooved array structures were labeled as Sample Am , Bm , Cm , Dm , Em and array
structures were labeled as Sample Am, Bm, Cm, Dm, Em and Fm, respectively.
Fm , respectively.

Micro-grinding machining
Figure 1. Micro-grinding
Figure machining scheme
scheme and
and photo
photo of
of mold
mold core: (a)
(a) Schematic
Schematic diagram
diagram of
of
V-grooved structures machining; (b) Photo
Photo of
of micro-grinding.
micro-grinding.
Table 1. Micro-grinding conditions of mold core using a V-tip diamond grinding wheel.
Table 1. Micro-grinding conditions of mold core using a V-tip diamond grinding wheel.
CNC Grinder SMART B818 III
CNC grinder SMART B818 Ⅲ
SD3000, SD3000, resin
resin bond, bond, diameter
diameter D = 150
D = 150 mm, mm,
width B =width B = 4 mm,
4 mm,
Diamond
Diamondgrinding
grindingwheel
wheel Wheel
Wheel speed N speed = 3000 r/min
= 3000Nr/min
Workpiece
Workpiece Ti3 SiC2 mold
Ti3SiC2 ceramic ceramic mold core
core
Rough machining Feed speed vf = 1000 mm/min, depth of cut a = 5 µm
Rough machining Feed speed vf = 1000 mm/min, depth of cut a = 5 µm
Finish machining Feed speed vf = 100 mm/min, depth of cut a = 1, Σa = 10 µm
Finish machining Feed speed vf = 100 mm/min, depth of cut a = 1, a = 10 µm
Coolant Emulsion
Coolant Emulsion

Table 2. The designed V-grooved structure parameters of mold cores.

Table 2. The designed V-grooved structure parameters of mold cores.
Sample V-Groove Angle α ( ) ◦ V-Groove Depth h (µm) V-Groove Space b (µm)
Sample V-groove angle α (°) V-groove depth h (µm) V-groove space b (µm)
A m Am 90 90 100 100 400
400
Bm 90 100 500
Bm 90 100 500
Cm 90 100 600
Cm D 90 90 100 150 600
400
m
Dm Em 90 90 150 150 400
500
Em Fm 90 90 150 150 500
600
Fm 90 150 600
2.2. Micro Injection Molding of Micro-Structured Polymers
2.2. Micro Injection Molding of Micro-Structured Polymers
The V-grooved array structures of mold core surface can be replicated on the surface of workpieces
TheaV-grooved
through array
micro injection structures
molding of mold
machine core 6/10P,
(Babyplast surface can be replicated
Cronoplast on Spain)
Sl, Barcelona, the surface of
as shown
workpieces
in Figure 2a.through a micro
The highly injection
efficient and molding
accurate machine (Babyplast
micro injection 6/10P,machine
molding Cronoplast
was Sl, Barcelona,
very suitable
Spain)
for massas production
shown in Figure 2a. The highly
and processing efficient and accurate
of all thermoplastic micro injection
micro precision molding
parts due machine
to its metal ball
was very suitable
plasticizing systemforand
mass production
piston injectionand processing
system. Figureof2b
allshows
thermoplastic micro
the working precision
principle of parts due
the micro
to its metal
injection ball plasticizing
molding machine. Thesystem and piston
polypropylene (PP)injection system.
particles (B310, Figure
Lotte 2b shows
Chemical the working
Corporation, Seoul,
principle
Korea) were of the micro
chosen injectionworkpiece
as polymer molding machine.
materials The polypropylene
and were placed in a(PP) particles
hopper in this(B310, Lotte
experiment.
Chemical Corporation, Seoul, Korea) were chosen as polymer workpiece materials and were placed
in a hopper in this experiment. The flow rate, density, thermal deformation temperature and
melting point of polymer material were 0.5 g/ 10min, 0.9 g/cm3, 110 °C and 167 °C, respectively. The
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The flow rate, density, thermal deformation temperature and melting point of polymer material were
0.5
mold 0.9 g/cm3 , 110 ◦ Carray
g/10 min,with and 167 ◦ C, respectively. The mold core with V-grooved array structures
mold core
core with V-grooved
V-grooved array structures
structures was
was installed
installed in
in the
the rear
rear mold.
mold. The
The polymer
polymer particles
particles
was
were installed in the rear mold. The polymer particles were first heated and plasticized, then were
werefirst
firstheated
heatedand
andplasticized,
plasticized,then
thenwere
weremelted
meltedandandinjected
injectedinto
intoaacavity
cavityofoffront
frontmold
moldthrough
through
melted
the and injected into a cavity of front mold through the nozzle under the action of plunger driven
thenozzle
nozzleunder
underthetheaction
actionof ofplunger
plungerdriven
drivenbybythe
themotor.
motor.Next,
Next,the
thecavity
cavitywould
wouldbe becooled
cooledafter
after
by the
holding motor. Next,
pressure forthe
a cavity
certain would
time. be cooled
Finally, after
the holding pressure
micro-structured for
polymera certain
was time.
formed Finally,
when the
holding pressure for a certain time. Finally, the micro-structured polymer was formed when the
micro-structured
front polymer was formed when the front and rear molds were simultaneously released.
frontand
andrear
rearmolds
moldswere
weresimultaneously
simultaneouslyreleased.
released.

Figure
Figure 2.2. Photo
Figure 2. Photoand
Photo andworking
and workingprinciple
working principleof
principle ofofthe
the micro
the micro
micro injection
injection molding
injection machine:
molding
molding (a)
machine:
machine: (a) photo;
(a) (b)
photo;
photo; (b)
working
(b) principle.
working
working principle.
principle.

Figure333shows
Figure shows the
showsthe design
thedesign sketches
sketchesofof
designsketches the
the
of mold
mold
the mold frame
frame and
frame and mold
mold
and core.
core.
mold The
The
core. structural
structural
The diagram
diagram
structural of
diagram
of
the the whole
whole moldmold frame
frame was was shown
shown in in Figure
Figure 3a. 3a. Figure
Figure 3b 3b
shows shows
the the schematic
schematic
of the whole mold frame was shown in Figure 3a. Figure 3b shows the schematic diagram of the diagram
diagram of the of the
front
front
front mold.
mold. The
The melted
The melted
mold. and
and plasticized
and plasticized
melted polymer
polymer
plasticized materials
materials
polymer were
wereinjected
were injected
materials into
into the
injected the
the cavity
cavity
into of the of
cavity of the
front front
themold
front
mold
through through
the the
pouring pouring
gate. gate.
Figure Figure
3c 3c
shows shows
the the
schematicschematic
diagram diagram
of the of
rear the
mold
mold through the pouring gate. Figure 3c shows the schematic diagram of the rear mold installedrear mold
installed installed
with the
with
mold the
with core. mold core.
Figurecore.
the mold Figure
3d shows
Figure 3d
the3d shows
schematic the
shows the schematic
diagram diagram
of the diagram
schematic of the
mold coreofwith mold
theV-grooved core with
mold corestructures V-grooved
ground
with V-grooved
structures
by ground
micro-grinding by micro-grinding
technology. technology.
structures ground by micro-grinding technology.

Figure
Figure 3.3.The
Figure3. The design
Thedesign sketches
designsketches
sketchesofof mold
ofmold frame
moldframe and
frameand mold
andmold core:
moldcore: (a)
core:(a) the
(a)the whole
thewhole mold
wholemold frame;
moldframe; (b)
frame;(b) the
(b)the front
thefront
front
mold;
mold; (c)
mold;(c) the
(c)the rear
therear mold;
rearmold; (d)
mold;(d) the
(d)the mold
themold core.
moldcore.
core.

Figure
Figure444shows
Figure shows
shows the
thethe micro
micro injection
injection
micro molding
molding
injection process
process
molding of
of micro-structured
of micro-structured
process polymer.
polymer.
micro-structured After the
polymer. After the
micro
After the
micro injection
injection molding,molding,
the the
V-groove V-groove
of the moldof the
core mold
was core was
duplicated onduplicated
the surface on
of the
the
micro injection molding, the V-groove of the mold core was duplicated on the surface of the surface
polymer toof the
form
polymer
polymerto toform
forman
aninverted
invertedV-shaped
V-shapedgroove
groovestructure.
structure.The
TheV-groove
V-grooveparameters
parametersofofmicro-ground
micro-ground
mold core were described as V-groove angle α 1, V-groove depth h1 and V-groove space b1. The
mold core were described as V-groove angle α1, V-groove depth h1 and V-groove space b1. The
V-groove
V-groove parameters
parameters of of micro-structured
micro-structured polymer
polymer were
were described
described as
as V-groove
V-groove angle
angle αα22,, V-groove
V-groove
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an inverted V-shaped groove structure. The V-groove parameters of micro-ground mold core were
described as V-groove angle α1 , V-groove depth h1 and V-groove space b1 . The V-groove parameters
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of micro-structured polymer were described as V-groove angle α2 , V-groove depth h2 and V-groove
space hb22 .and
depth TheV-groove
surface qualities
space bof
2. micro-structured polymer
The surface qualities at groove side and
of micro-structured groove at
polymer bottom
groove depend
side
and groove bottom depend on the groove side and groove top of mold core, respectively. Themold
on the groove side and groove top of mold core, respectively. The six groups of micro-ground six
cores were employed to conduct micro injection molding experiments
groups of micro-ground mold cores were employed to conduct micro injection molding under the same conditions.
According tounder
experiments preliminary experimental
the same conditions.experiences,
Accordingthe to melting temperature,
preliminary injection
experimental speed, holding
experiences, the
pressuretemperature,
and holding injection
time was speed,
set as 210 ◦ C, 40pressure
mm/s, 7 MPa and 5 s, respectively.
melting holding and holding time was set After
as 210micro
°C, 40injection
mm/s,
7molding,
MPa andthe5 corresponding
s, respectively.micro-structured polymer
After micro injection samplesthe
molding, were defined as Awmicro-structured
corresponding , Bw , Cw , Dw , Ew
and F
polymer , respectively.
w samples were defined as Aw, Bw, Cw, Dw, Ew and Fw, respectively.

Figure
Figure4.4.Principle
Principleofofmicro
microinjection
injectionmolding
moldingofofthe
themicro-structured
micro-structuredpolymer.
polymer.

In order to
In toinvestigate
investigatethe influences
the influencesof melt temperature
of melt T, injection
temperature speed v,
T, injection injection
speed pressure
v, injection
P and holding
pressure P andtime t on filling
holding time rate
t onoffilling
micro-structures polymer, the experimental
rate of micro-structures polymer, the parameters were
experimental
designed and presented in Table 3. Under each process parameter condition, thirty
parameters were designed and presented in Table 3. Under each process parameter condition, micro-molding
polymer
thirty samples werepolymer
micro-molding produced, and five
samples samples
were were randomly
produced, selected were
and five samples for testing and averaging.
randomly selected
for testing and averaging.
Table 3. Experimental parameter lists of micro injection molding.
Table 3. Experimental parameter lists of micro injection molding.
Melt Temperature Injection Speed Injection Pressure Holding Time
No. ◦ C)
T (
Melt temperature v (mm/s)
injection speed P (MPa)
injection pressure t (s)
holding time
No.
1 T (°C) 200 v (mm/s)40 7
P (MPa) 3 t (s)
1 2 200 205 40 40 7 7 3 3
3 210 40 7 3
2 4
205 215
40 40 7
7 3
3
3 5 210 220 40 40 77 3 3
4 6 215 210 40 30 77 3 3
5 7 220 210 40 35 77 3 3
6 8 210 210 30 45 7 7 3 3
9 210 50 7 3
7 10
210 210
35 40 5
7 3
3
8 11 210 210 45 40 6 7 3 3
9 12 210 210 50 40 87 3 3
10 13 210 210 40 40 95 3 3
14 210 40 7 1
11 210 40 6 3
15 210 40 7 2
12 16 210 210 40 40 7 8 4 3
13 17 210 210 40 40 7 9 5 3
14 210 40 7 1
15 210 40
2.3. Measurement of Micro-Grooved Mold Cores and Polymers 7 2
16 210 40 7 4
17 High-resolution
210 scanning electron microscopy
40 (SEM, FEI Quanta
7 450FEG and Apreo
5 S, FEI
Company, Hillsboro, OR, USA) was used to detect the surface topographies of micro-structured mold
cores.
2.3. The 3D laser
Measurement scanning microscope
of Micro-Grooved (VK-250,
Mold Cores Keyence, Osaka, Japan) was employed to measure
and Polymers
High-resolution scanning electron microscopy (SEM, FEI Quanta 450FEG and Apreo S, FEI
Company, Hillsboro, OR, USA) was used to detect the surface topographies of micro-structured
mold cores. The 3D laser scanning microscope (VK-250, Keyence, Osaka, Japan) was employed to
measure the 3D topographies and section profiles of micro-structured mold cores. A probe stepper
Micromachines 2019, 10, 253 6 of 15

the 3D topographies and section profiles of micro-structured mold cores. A probe stepper (D-300,
KLA-Tencor, Milpitas, CA, USA) was employed to measure the section profiles of micro-structured
polymers. Through the section profiles curve, the surface roughness and V-tip angle can be obtained
through the data analysis software. The presented result was the average value of five measured data.

3. Results and Discussions

3.1. Surface Topographies and Profiles of Micro-Ground Mold Core

Figure 5 shows the 3D topographies and section profiles of the mold core with micro-grooved array
structures after micro-grinding. It is shown that the regular and smooth V-grooved array structures
were integrally fabricated on the surfaces of mold cores. The micro-ground V-grooved structure
parameters were shown in Table 4, which were roughly consistent with designed V-grooved parameters
shown in Table 2. The V-tip angle α was derived from the V-groove profile curve measured by the 3D
laser scanning microscope. The micro-ground angle errors of V-groove were ranged from 0.88◦ –1.87◦
and the average angle error was 1.38◦ . The micro-ground average depth and space errors of V-groove
were 2.62 µm and 2.73 µm, respectively. The actual V-groove space of mold core was slightly larger
than the theoretical value, which was mainly affected by the end face jump of the diamond wheel.

Table 4. The V-grooved structure parameters of micro-ground mold cores.

Sample V-Groove Angle α1 (◦ ) V-Groove Depth h1 (µm) V-Groove Space b1 (µm)

Am 90.88 99.72 400.43
Bm 91.87 106.64 503.17
Cm 91.80 100.37 604.17
Dm 91.17 148.10 401.97
Em 91.19 152.61 506.52
Fm 91.35 153.93 599.86

Figure 6 shows the SEM photos of micro-ground mold core surfaces. As seen from the SEM
observations, the surface topography characteristics of the V-groove were substantially identical to
measured 3D topographies shown in Figure 5. It is also seen that the surface of V-groove side was
smoother than the one of groove top (un-ground surface). The Sample Dm had the smoothest and
most regular V-groove surface compared with the other Samples.
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Figure 5. 3D topographies and profiles of micro-ground mold cores: (a) Sample Am; (b) Sample Bm;
Figure 5. 3D topographies and profiles of micro-ground mold cores: (a) Sample Am ; (b) Sample Bm ;
(c) Sample Cm; (d) Sample Dm; (e) Sample Em; (f) Sample Fm.
(c) Sample Cm ; (d) Sample Dm ; (e) Sample Em ; (f) Sample Fm .
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Figure
Figure 6. 6.
6. SEM
SEMSEM photos
photos
photos of of micro-ground
ofmicro-ground
micro-ground moldmold
mold cores:
cores:
cores: (a)
(a)(a) Sample
Sample AmAA
Sample m; (b)
; m(b) Sample
Sample
; (b) B(c)
Bm;B
Sample m; (c) Sample
Sample CmC m; (d)
; (d)
Figure m ; (c) Sample Cm ;
Sample
Sample D mD
; m; (e)
(e) Sample
Sample E m;E m; (f)
(f) Sample
Sample Fm .
(d) Sample Dm ; (e) Sample Em ; (f) Sample Fm .Fm.

3.2.3.2.
Surface
Surface Topographies
Surface andand
Topographies
Topographies Profiles of Micro-Structured
Profiles Polymers
of Micro-Structured
Micro-Structured Polymers
Polymers
Figure
Figure 77shows
7 shows
shows thethe
SEM
the
SEMtopographies
SEM topographies of micro-structured
topographies of of polymers
micro-structured
micro-structured after micro
polymers
polymers injection
after
after micro micro molding.
injection
injection
As seen
molding.
molding. from
AsAs the
seen SEM
seenfrom photos,
fromthethe
SEM the
SEM V-shaped
photos,
photos, thethegroove
V-shaped
V-shaped array structures
groove
groove array
array of mold
structures
structures cores
of of were
moldmold preferably
cores
cores werewere
replicated
preferably
preferably onreplicated
polymers
replicated onon topolymers
form an
polymers inverted
to to
formformanan V-shaped
inverted
inverted groove groove
V-shaped
V-shaped structure.
groove It is shown
structure.
structure. It isIt shown that that
is shown the
that
micro-structured
the micro-structuredsurface of
surfaceD of wasD w the
was smoothest
the smoothest and the
and surface
the micro-structured surface ofwDw was the smoothest and the surface roughness of groove side a Ra
the roughness
surface roughness of groove
of groove side R
side
reached
reached 0.052 µm.
0.052
µm.µm. Moreover,
Moreover,
Moreover, it isit seen
is seen that
that V-groove
thethe V-groove
V-groove sideside
of of
thethe micro
micro injection
injection molded
molded polymer
polymer
was smoother
was smoother
smoother than
than the
than one
thethe
oneofof
onethe
of
the mold
themold core
mold (see
corecore Figures
(see(see 6d and
Figures
Figures 6d6d 7d).
andandIt is
7d). observed
7d). It observed
It is that there
is observed that thatwere
there
there many
werewere
cracks
many
many and
cracks melted
cracksandand polymers
melted
melted on the
polymers
polymers micro-formed
onon thethe surfaces
micro-formed
micro-formed for Samples
surfaces
surfaces B
forfor , C
wSamples
Samples , and
w BwB F .
, wCw,wC The reason
, and
, wand . is
Fw.FwTheThe
that
reasontheismicro-ground
reason is that
that thethe surface qualities
micro-ground
micro-ground surface
surface ofqualities
corresponding
qualities of of mold cores
corresponding
corresponding mold were
mold cores notwere
cores satisfactory,
were notnot leading
satisfactory,
satisfactory,
to leading
difficult
leading demolding
to to difficult
difficult in the micro
demolding
demolding injection
in inthethe molding
micro
micro process.
injection
injection For all
molding
molding micro-formed
process.
process. ForForallall polymers,
micro-formed
micro-formed the
V-groove
polymers,
polymers, side
thethewas smoother
V-groove
V-groove side than
sidewas was the V-groove
smoother
smoother thanbottom.
than thethe This is
V-groove
V-groove because
bottom.
bottom. the
This surface
This quality
is because
is because of
thethe groove
surface
surface
bottom
quality
quality of of
of polymers
groove
groove depended
bottom
bottom of of on the un-ground
polymers
polymers depended
depended groove
on on
thethetop of mold
un-ground
un-ground cores.
groove
groove toptopof of
moldmold cores.
cores.

Figure
Figure 7. 7. SEM
7. SEM
SEM photos
photos
photos of of micro-structured
ofmicro-structured
micro-structured polymers:
polymers:
polymers: (a)
(a)(a) Sample
Sample AwAA
Sample w; (b)
; w(b) Sample
Sample
; (b) B(c)
Bw;B
Sample w; (c) Sample
Sample Cw;C(d)
w; (d)
Figure w ; (c) Sample Cw ;
Sample
Sample D
Dw;D
(d) Sample ;
(e)
w (e) Sample E ; (f) Sample
Sample Ew; (f) Sample Fw.
w Fw .
w ; (e) Sample Ew ; (f) Sample Fw .

Because
Because
Because thethe polymer
polymer
polymer waswas nonopaque,
nonopaque,
nonopaque, thethe cross-sectional
cross-sectional
cross-sectional profiles
profiles of of micro-structured
micro-structured polymer
polymer
surfaces
surfaces were
were
were captured
captured
captured bybyaby a contact
a contact
contact step step
step profiler.
profiler.
profiler. Figure
Figure
Figure 8 the
shows
8 shows
8 shows thethe V-grooved
V-grooved
V-grooved section
sectionsection
profile profile
profile
curves
curves
curves of micro-structured
of micro-structured
of micro-structured polymers
polymerspolymers after
after microafter micro injection
micromolding.
injection injectionThe molding.
molding.
V-grooved The V-grooved
Thestructure
V-grooved structure
structure
parameters of
parameters
parameters
polymers of polymers
areofshown
polymers areare
in Table 5. shown
shown in in
The V-tip Table
Table 5.curve
5. The
profile The V-tip
V-tip anprofile
hadprofile curve
arc curve
radius hadhad
due toan
an arcarc
the radius
radius
V-tip arcduedueto to
radius ofthe
the
V-tip
V-tip arc
arc radius
radius of of
thethe mold
mold core
core andand trued
trued diamond
diamond grinding
grinding wheel.
wheel. Compared
Compared
the mold core and trued diamond grinding wheel. Compared with designed V-grooved parameters with
with designed
designed
V-grooved
V-grooved parameters
parameters shown
shown in in Table
Table 2, the
2, the micro-formed
micro-formed angle
angle errors
errors of of V-groove
V-groove ononthethe surface
surface
of of micro-structured
micro-structured polymers
polymers were
were ranged
ranged from
from 0.02°–0.88°
0.02°–0.88° andandthethe average
average angle
angle error
error waswas only
only
micro-forming accuracy. The results were also consistent with the SEM photographs shown in
Figure 7.

Table 5. The V-grooved structure parameters of micro-structured polymers.

Micromachines 2019, 10, 253 9 of 15
Sample V-groove angle α2 (°) V-groove depth h2 (µm) V-groove space b2 (µm)
Aw 89.98 98.74 400.40
shown in Table 2, the micro-formed angle errors of V-groove on the surface of 500.40
B w 89.98 106.50 micro-structured
Cw were ranged from
polymers 89.120.02◦ –0.88◦ and the average
98.43 600.50
angle error was only 0.46◦ . The micro-formed
D w 90.81 147.15 398.00
average depth and space errors of V-groove were 2.42 µm and 1.12 µm, respectively. Compared with
Ew profiles, it is found
the V-tip 89.26 that Sample Dw had the 150.77
highest micro-forming accuracy.501.40
The results were
also Fconsistent
w with the90.26
SEM photographs shown in151.55Figure 7. 598.00

Figure 8.
Figure 8. The profiles
profiles of
of micro-structured
micro-structuredpolymers:
polymers:(a)
(a)Sample
SampleAA
w;w(b) Sample
; (b) BwB; w
Sample (c); (c)
Sample Cw;C(d)
Sample w;
Sample
(d) Dw;D(e)
Sample w ; Sample
(e) E
Samplew ; (f)
Ew Sample
; (f) F
Sample
w . Fw .

Table 5. The V-grooved structure parameters of micro-structured polymers.

3.3. Machining Accuracy of Micro-Ground Mold Core and Filling Rate of Micro-Formed Polymer
Sample the measurement
Although V-Groove Angle α2 ( )
instruments
◦ V-Groove Depth
of mold core h2 polymer
and (µm) V-Groove
profiles Space
are b2 (µm)based
different,
Aw measurement experiences,
on previous 89.98 98.74results of the two instruments
the measurement 400.40 are almost
Bw 89.98 106.50
the same. Through comparing with the V-groove profiles of mold cores and micro-tip 500.40 of grinding
Cw 89.12 98.43 600.50
wheel tool, the profile error distribution and angle error curve can be obtained. The profile error em
Dw 90.81 147.15 398.00
was defined
Ew as the height deviation
89.26 between the V-groove
150.77 profile of mold core501.40
and the micro tip
profile ofFwdiamond grinding wheel. The V-groove angle
90.26 151.55 relative error of mold core αm can be
598.00
calculated by the following formula:
3.3. Machining Accuracy of Micro-Ground Mold Core
|  and
1 | Filling Rate of Micro-Formed Polymer
m   100% (1)
Although the measurement instruments of mold  core and polymer profiles are different, based on
previous measurement experiences, the measurement results of the two instruments are almost the
Where α is the V-groove angle of the wheel tool tip; α1 is the V-groove angle of
same. Through comparing with the V-groove profiles of mold cores and micro-tip of grinding wheel
micro-structured mold core. Because of the misalignment of the end face of the diamond grinding
tool, the profile error distribution and angle error curve can be obtained. The profile error em was
wheel, the V-tip angle of mold core surface was generally larger than the one of the wheel tool tip.
defined as the height deviation between the V-groove profile of mold core and the micro tip profile of
diamond grinding wheel. The V-groove angle relative error of mold core αm can be calculated by the
following formula:
|α − α1 |
αm = × 100% (1)
α
where α is the V-groove angle of the wheel tool tip; α1 is the V-groove angle of micro-structured mold
core. Because of the misalignment of the end face of the diamond grinding wheel, the V-tip angle of
Micromachines 2019, 10, 253 10 of 15
Micromachines 2019, 10, x 10 of 15

The form
mold core accuracy
surface was of generally
mold corelargerγ canthan
be the
defined
one of asthe
thewheel
difference value
tool tip. The between a peakofand
form accuracy molda
valley
core γ can
at the
be profile
definederror
as thecurve [21]. value between a peak and a valley at the profile error curve [21].
difference
Figure 9 shows
shows thetheangle
anglerelative errorαα
relativeerror mmandand form
form accuracy
accuracy γ of
γ of moldmoldcores. According
cores. According to the
to
V-groove
the V-grooveprofile curves
profile curvesof mold
of moldcore and
core andwheel
wheel tool
tooltiptipasasshown
shownininFigure
Figure9a,9a, the
the form
form error
distribution curve
distribution curveofofmold
mold corecore
can can be obtained
be obtained as shownas shown
in Figure in 9b.
Figure 9b. It indicated
It indicated that the
that the maximum
maximum
profile errorprofile
emerged error emerged
at the at the tipThis
tip of V-groove. of V-groove.
is because This is because
the micro machiningthe micro machining
of V-shaped of
tips has
V-shaped
always tipsa has
been alwaysbottleneck
technical been a technical
so thatbottleneck
the arc radiusso that
wouldthe arc radius
always bewould always
existent. be existent.
It is shown that
It is shown
V-tip profilethat
errorV-tip profile error mold
of micro-ground of micro-ground mold corewithin
core can be controlled can be5controlled
µm. Figure within 5 µm.
9c shows theFigure
angle
9c shows
relative errors αm of relative
the angle all molderrors
cores, αwhich
m of all
weremold cores,from
ranged which were ranged
1.0%–2.1%. from 1.0%–2.1%.
The average The
angle relative
average
error angle relativemold
of micro-ground errorcores
of micro-ground
was only 1.53%. mold cores the
Through wasform
onlyerror
1.53%. Through curve
distribution the formshownerror
in
distribution
Figure 9b, thecurve
formshown
accuracy γ can be9b,
in Figure the form
obtained asaccuracy
shown inγFigure can be9d. obtained as shown
It is shown in Figure
that mold core D9d.
m
It is the
had shown that mold
minimum formcore Dm had
accuracy of the
4.05minimum
µm. Besides form accuracy
mold cores Bof m 4.05
and µm. Besides
Cm , the mold cores
micro-ground Bm
form
and Cm, theofmicro-ground
accuracies other mold cores formwere
accuracies
below 10of other
µm. mold cores were below 10 µm.

Figure 9. The angle relative error αmm and

and form accuracy γγ of
form accuracy of mold
mold core:
core: (a)
(a)V-groove
V-groove profile curves of
mold core
wheel tip and mold core D
Dmm; (b) form error distribution of mold core
core D
Dm m; (c) angle relative error α
αmm;;

(d) form accuracy γ.

γ.

Through comparing with

Through comparing with the
the V-groove
V-groove profiles
profiles of
of mold
mold cores
cores and
and polymers, the profile
polymers, the profile error
error
distribution
distribution and
andangle
angleerror cancan
error be obtained. Therefore,
be obtained. the V-groove
Therefore, angel relative
the V-groove error of polymer
angel relative error of
α w can beαcomputed
polymer as follows:
w can be computed as follows:
|α − α2 |
αw = |1   | × 100% (2)
 w  1α1 2  100% (2)

where α2 is the V-groove angle of micro-structured 1polymer. The filling rate of micro injection molding
η canWhere
be obtained by V-groove
α2 is the the following equation:
angle of micro-structured polymer. The filling rate of micro injection
molding η can be obtained by the following equation:
1 X |h1 − h2 |
η = 1− × 100% (3)
N1 |h hh |
  1   1 1 2  100% (3)
N h
where h1 is the V-groove depth value of mold core, h2 is1 the V-groove depth value of polymer workpiece,
N is the datahpoints
Where 1 is theof the measured
V-groove depthV-groove profile.
value of mold core, h2 is the V-groove depth value of polymer
Figure N
workpiece, 10isshows thepoints
the data angleofrelative error αV-groove
the measured w and filling rate η of micro-structured polymers.
profile.
Figure 10c shows the angle relative error
Figure 10 shows the angle relative error α w for all micro-structured
αw and filling rate η of polymers, which were
micro-structured ranged
polymers.
from
Figure0.4%–2.9%.
10c shows The average
the angle angleerror
relative relative error
αw for allofmicro-structured
micro-formed polymers
polymers,was onlywere
which 1.58%. It is
ranged
from 0.4%–2.9%. The average angle relative error of micro-formed polymers was only 1.58%. It is
shown that polymer Dw had the minimum angle relative error of 0.4%. It is also found that the V-tip
Micromachines 2019, 10, 253 11 of 15
Micromachines 2019, 10, x 11 of 15

angles of micro-structured
shown that polymer Dw hadpolymers the minimum wereangle
less relative
than theerroronesof of V-grooved
0.4%. It is alsomold
foundcores.
that theThis is
V-tip
because
angles of the injection molded
micro-structured polypropylene
polymers were less than (PP)the had
ones shrinkage
of V-grooved during
mold the
cores. cooling
This is process,
because
resulting in amolded
the injection decreasepolypropylene
in the V-groove angle.
(PP) had As observed
shrinkage from the
during Figure 10c, the
cooling largerresulting
process, the spaceinofa
V-groove
decrease in was,
thethe larger the
V-groove angle
angle. Asrelative
observed error
fromwas. The reason
Figure 10c, themay be the
larger thatspace
the larger the space
of V-groove of
was,
V-groove
the larger was, the faster
the angle the error
relative shrinkage
was. of Thethe micro-formed
reason may be that polymer was,the
the larger resulting
space of in V-groove
an increase in
was,
V-groove angle.
the faster the Figure 10d
shrinkage shows
of the the fillingpolymer
micro-formed rate η forwas,
all micro-structured polymers.
resulting in an increase It is seenangle.
in V-groove that
the workpiece
Figure 10d showsDwthe hadfilling rate η forfilling
the highest rate, which reached
all micro-structured polymers. up to 99.30%.
It is Through
seen that comparing
the workpiece Dw
with Figure
had the 9d filling
highest and Figure 10d, itreached
rate, which can be up basically concluded
to 99.30%. Through that the higher
comparing theFigures
with form accuracy
9d and 10d, of
mold
it can core machining
be basically was, the
concluded higher
that the filling
the higher rate accuracy
the form of the micro-formed
of mold corepolymer
machining was.
was,Besides, it is
the higher
also foundrate
the filling thatofthe
thelarger the depthpolymer
micro-formed or the depth-width
was. Besides, ratio
it isof V-groove
also found thatwas,the
thelarger
higher thethe filling
depth or
rate was.
the depth-width ratio of V-groove was, the higher the filling rate was.

Figure 10. The angle relative error α

The angle αw
w and
and filling rate η η of micro-structured polymer: (a)
(a) V-groove
profile curves of polymer
polymer D Dww and mold core Dm m;; (b)
(b) form error distribution of polymer Dww;; (c) angle

relative errors α
αww;; (d)
(d) filling
filling rates η.
rates η.

3.4. Surface
3.4. Surface Quality
Quality Analysis
Analysis of of Mold
Mold Core
Core and
and Injection
Injection Molded
Molded Polymers
Polymers
According to
According to the
the micro-forming principle of
micro-forming principle of micro-structured polymer fabricated
micro-structured polymer fabricated by by micro
micro
injection molding as shown in Figure 4, the surface qualities of the polymer
injection molding as shown in Figure 4, the surface qualities of the polymer at groove side and at groove side and
groove bottom depend on the micro-ground groove side and un-ground
groove bottom depend on the micro-ground groove side and un-ground groove top of mold core, groove top of mold core,
respectively. Figure
respectively. Figure 11a
11a shows
shows the the surface roughness R
surface roughness of groove
Raa of groove sides
sides of
of mold
mold cores
cores and
and polymers.
polymers.
The comparisons of surface roughness R between the groove top of mold
The comparisons of surface roughness Raa between the groove top of mold cores and groove bottom cores and groove bottom
of polymers
of polymers were were shown
shown in in Figure
Figure 11b.
11b. ItIt can
can bebe observed
observed thatthat the
the surface roughness R
surface roughness of groove
Raa of groove
sides of micro-ground mold cores and micro-formed polymers were ranged from 0.271–0.336 and
sides of micro-ground mold cores and micro-formed polymers were ranged from 0.271–0.336 µm µm
0.052–0.092
and µm, respectively.
0.052–0.092 µm, respectively. This indicated that thethat
This indicated surface
the qualities of injection
surface qualities of molded
injectionpolymers
molded
were betterwere
polymers thanbetter
the ones
than of the
mold cores.
ones The groove
of mold side groove
cores. The of micro-ground mold core Dmmold
side of micro-ground had the
coreleast
Dm
surface roughness R of 0.271 µm and the corresponding
had the least surfacea roughness Ra of 0.271 µm and the corresponding surfacesurface roughness R a of polymer
roughness DwRalso
a of
achieved D
polymer a wminimum value aofminimum
also achieved 0.052 µm. value
The surface
of 0.052 µm. TheRsurface
roughness a of the groove
roughnesssideRofa of
micro-formed
the groove
polymers can be maintained below 0.1 µm. It is also shown
side of micro-formed polymers can be maintained below 0.1 µm. It is also shown that the un-ground groove topthat
of mold
the
cores was much rougher than the micro-ground groove side, leading to
un-ground groove top of mold cores was much rougher than the micro-ground groove side, leading degradation in the surface
quality
to of groove
degradation in bottom
the surfaceof micro-structured
quality of groove polymers.
bottom of micro-structured polymers.
Micromachines 2019, 10, x 12 of 15
Micromachines 2019, 10, 253 12 of 15
Micromachines 2019, 10, x 12 of 15

Figure 11. Comparisons of surface roughness Ra of micro-structured mold cores and polymers: (a)
groove sides of mold core and polymer; (b) groove top of mold core and groove bottom of the
Comparisonsofofsurface
Figure 11. Comparisons surfaceroughness RaRof
roughness a of micro-structured
micro-structured mold
mold cores
cores andand polymers:
polymers: (a)
polymer.
(a) groove
groove sides
sides of mold
of mold corecore
andand polymer;
polymer; (b) groove
(b) groove top top of mold
of mold corecore
and and groove
groove bottom
bottom of
of the
the polymer.
polymer.
3.5. Relationship between Filling Rate of Micro-Structured Polymer and form Accuracy of Micro-Ground
Mold Core
3.5. Relationship
Relationship between Filling
Filling Rate
Rate ofof Micro-Structured
Micro-Structured Polymer
3.5. between Polymer andand form
form Accuracy
Accuracy of of Micro-Ground
Micro-Ground
Mold Core
MoldFigure
Core 12 shows the relationship between the filling rate of micro-structured polymer η and
form Figure
accuracy of micro-ground
12 shows moldbetween
the relationship core γ. the
Thefilling
micro-ground form accuracies
rate of micro-structured η andcores
of six mold
polymer form
Figure 12 shows the relationship between the filling rate of micro-structured polymer η and
accuracy of micro-ground mold core γ. The micro-ground form accuracies of six mold cores were
were 7.53 µm, 24.5 µm, 24.84 µm, 4.05 µm, 8.87 µm, and 9.59 µm, respectively. The corresponding
form accuracy of micro-ground mold core γ. The micro-ground form accuracies of six mold cores
filling
7.53 µm, rate of µm,
24.5 micro-formed polymers
24.84 µm, 4.05 µm, 8.87were
µm,86.33%,
and 9.5995.34%, 88.61%, 93.85%,
µm, respectively. 97.78% and 99.45%,
The corresponding filling
were 7.53 µm, 24.5 µm, 24.84 µm, 4.05 µm, 8.87 µm, and 9.59 µm, respectively. The corresponding
respectively. It is shown
rate of micro-formed that were
polymers the form
86.33%,accuracy
95.34%, of micro-ground
88.61%, moldand
93.85%, 97.78% core had arespectively.
99.45%, positively
filling rate of micro-formed polymers were 86.33%, 95.34%, 88.61%, 93.85%, 97.78% and 99.45%,
influences
It is shown onthatfilling rateaccuracy
the form of microofinjection molding.
micro-ground moldThe corefilling
had a rate of micro-structured
positively polymer
influences on filling rate
respectively. It is shown that the form accuracy of micro-ground mold core had a positively
basically increasedmolding.
of micro injection with theThedecrease
fillingof theofform
rate accuracy of micro
micro-structured mold
polymer core. This
basically indicated
increased withthat
the
influences on filling rate of micro injection molding. The filling rate of micro-structured polymer
the higherofmachining
decrease accuracy
the form accuracy ofof the mold core.
micro core was, the higherthat
This indicated thethe
filling ratemachining
higher of micro injection
accuracy
basically increased with the decrease of the form accuracy of micro mold core. This indicated that
molding
of the mold was.core was, the higher the filling rate of micro injection molding was.
the higher machining accuracy of the mold core was, the higher the filling rate of micro injection
molding was.

Figure
Figure 12.
12. The
The relationship
relationship between
between the
the filling
filling rate
rate of
of micro-structured polymer ηη and
micro-structured polymer and form
form accuracy
accuracy
of
of micro-ground
micro-ground mold core γ. γ.
Figure 12. The relationship between the filling rate of micro-structured polymer η and form accuracy
3.6. Effects
3.6. Effects of Micro
Micro Injection
of micro-ground
of Injection
mold coreMolding
γ.
Molding Parameters on
Parameters on the
the Filling
Filling Rate
Rate of
of Micro-Structured
Micro-Structured Polymer
Polymer
Figure 13
Figure 13 shows
shows thethe filling
filling rate
rate of
of micro-structured
micro-structured polymer
polymer η versus
versus micro
micro injection
injection molding
molding
3.6. Effects of Micro Injection Molding Parameters on the Filling Rate of ηMicro-Structured Polymer
parameters including
parameters including melting
meltingtemperature
temperatureT,T,injection
injectionspeed
speedv, injection pressure
v, injection P and
pressure P holding time
and holding
t. As Figure
seen 13 shows
from Figure the filling
10a,b, the rate of micro-structured
filling rate η of polymer
micro-formed η versus
polymer microfirst
basically injection molding
increased and
time t. As seen from Figures 10a and 10b, the filling rate η of micro-formed polymer basically first
parameters
then decreased including melting
withdecreased
the increase temperature T, injection speed v, injection pressure P and holding
increased and then withofthemelt temperature
increase of meltTtemperature
and injectionT speed v. The filling
and injection speed v.rateTheof
time t. As seenpolymer
micro-formed from Figures
was 10a and
ranged from10b, the filling rateand
98.25%–99.30% η of micro-formedrespectively.
92.86%–99.30%, polymer basically first
According
filling rate of micro-formed polymer was ranged from 98.25%–99.30% and 92.86%–99.30%,
increased
to the resultsandshown
then decreased
in Figure with
10c,d,the theincrease
change of meltoftemperature
range T and injection speed v. The
respectively. According to the results shown in Figures 10cfilling
and 10d, ratethe
with injection
change rangepressure P rate
of filling and
filling
holding rate of micro-formed
time tpressure
was 91.19%–99.30% polymerand was ranged
92.71%–99.30%, from 98.25%–99.30%
respectively. and 92.86%–99.30%,
Therefore, the experimental
with injection P and holding time t was 91.19%–99.30% and 92.71%–99.30%, respectively.
respectively. According to the results shown in the
Figures 10c and 10d, the change rate
rangeof of filling rate
Therefore, the experimental results showed that the injection pressure hadfilling
results showed that the injection pressure had greatest influence on the greatest the injection
influence on
with
formed injection
polymer,pressure
while P and
the holding
melt time t had
temperature wasthe91.19%–99.30%
least influence. andIn92.71%–99.30%,
summary, when respectively.
the melting
filling rate of the injection formed polymer, while the melt temperature had the least influence. In
Therefore, the experimental results showed that the injection pressure had the greatest influence on
filling rate of the injection formed polymer, while the melt temperature had the least influence. In
 Micromachines 2019, 10, x 13 of 15
Micromachines 2019, 10, 253 13 of 15

summary, when the melting temperature, injection speed, injection pressure and holding time was
210 °C, 40 mm/s, 7 MPa and 5 s, respectively, the filling rate of micro-structured polymer can reach
temperature, injection speed, injection pressure and holding time was 210 ◦ C, 40 mm/s, 7 MPa and 5 s,
a maximum value of 99.30%.
respectively, the filling rate of micro-structured polymer can reach a maximum value of 99.30%.

Figure
Figure 13.13.
TheThe filling
filling rate
rate of of micro-structured
micro-structured polymer
polymer η versus
η versus micro
micro injection
injection molding
molding parameters:
parameters:
(a)(a) Melting
Melting temperature
temperature T; (b)
T; (b) injection
injection speed v; (c)
speed v; (c) injection
injection P; (d)
pressure
pressure P; (d) holding
holding t. t.
time
time

4. Conclusions
4. Conclusions
The micro-grinding technology using a trued V-tip diamond grinding wheel is proposed to
The micro-grinding technology using a trued V-tip diamond grinding wheel is proposed to
machine regular and accurate micro-grooved array structures on the surface of the mold core. The
machine regular and accurate micro-grooved array structures on the surface of the mold core. The
micro-structured polymers are efficiently and precisely fabricated using micro injection molding based
micro-structured polymers are efficiently and precisely fabricated using micro injection molding
on a micro-ground mold core. It may realize low-cost mass-production of micro-structured polymer
based on a micro-ground mold core. It may realize low-cost mass-production of micro-structured
components. The main results can be concluded as follows:
polymer components. The main results can be concluded as follows:
1. The1. highest form accuracy
The highest of the micro-ground
form accuracy mold core and
of the micro-ground fillingcore
mold rate of
andthefilling
micro-structured
rate of the
polymer can reach
micro-structured to 4.05can
polymer and 99.30%,
µm reach to 4.05respectively. The minimum
µm and 99.30%, angle The
respectively. relative error of angle
minimum the
micro-formed
relative polymer
error of the is only 0.4%.
micro-formed polymer is only 0.4%.
2. The2. surface
The surface roughness
roughness Ra of micro-formed
Ra of micro-formed polymerpolymer side
side can be can be maintained
maintained below
below 0.1 µm. The0.1 µm.
least
TheRaleast Ra of micro-ground
of micro-ground mold coremoldsidecore sideµm,
is 0.271 is 0.271 µm,
and the and the corresponding
corresponding Ra of micro-formed
Ra of micro-formed polymer
polymer
can also canreach
also areach a minimum
minimum value of value
0.052ofµm.
0.052 µm.
3. The3. form
The accuracy
form accuracy of micro-ground
of micro-ground mold coremold coreinfluences
positively positivelytheinfluences
filling rate the filling rate of
of micro-formed
micro-formed
polymer. The polymer. The of
filling rate filling rate of micro-structured
micro-structured polymer
polymer basically basically
increases increases
with with the
the increasing
increasing
machining machining
accuracyaccuracy of the
of the mold mold core.
core.
4. The4. The injection
injection pressure
pressure has has
the the greatest
greatest influence
influence on on
thethe filling
filling rate
rate of of micro-formed
micro-formed polymer,
polymer,
while thethe
while melt temperature
melt temperature hashas
thethe
least influence.
least influence.
Author Contributions: Conceptualization, Y.J.L. and C.Z.; data curation, F.C.; formal analysis, Y.J.L.; funding
Author Contributions:
acquisition, X.W. and Conceptualization, Y.L.F.C.;
Y.L.; investigation, (Yanjun Lu) and C.Z.;
methodology, data
Y.J.L. andcuration, F.C.; formal analysis,
X.W.; supervision, Y.L. andY.L.
L.L.;
(Yanjun Lu); fundingdraft,
writing—original acquisition, X.W. and Y.L.; investigation,
Y.J.L.; writing—review & editing, C.Z.F.C.; methodology, Y.L. (Yanjun Lu) and X.W.;
supervision, Y.L. and L.L.; writing—original draft, Y.L. (Yanjun Lu); writing—review & editing, C.Z.
Funding: This research was funded by the National Natural Science Foundation of China (grant numbers
Funding: This research was funded by the National Natural Science Foundation of China (grant numbers
51805334, 51575360
51805334, 51575360 and and 51675347),
51675347), the Fundamental
the Fundamental ResearchResearch Funds
Funds for for the Shenzhen
the Shenzhen UniversityUniversity (grant
(grant number
numberthe2018031),
2018031), Science andtheTechnology
Science and Technology
Planning Planning
Project of GuangdongProject of Guangdong
Province Province
(grant numbers (grant numbers
2016A040403043 and
2017A010102003),
2016A040403043 theand
Youth Projects for Creative
2017A010102003), TalentsProjects
the Youth of Educational Commission
for Creative TalentsofofGuangdong
EducationalProvince (grant of
Commission
number 2015KQNCX009)
Guangdong and the
Province (grant Opening
number Project of the National
2015KQNCX009) and theEngineering SearchofCenter
Opening Project of Near-net-shape
the National Engineering
Forming for Metallic Materials (grant numbers 2015001 and 2017008).
Search Center of Near-net-shape Forming for Metallic Materials (grant numbers 2015001 and 2017008).
Micromachines 2019, 10, 253 14 of 15

Acknowledgments: The authors would also gratefully acknowledge the instrumental analysis center of Shenzhen
University (Xili Campus).
Conflicts of Interest: The authors declare no conflict of interest.

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