Precise and fast molding of micro glass components by micro injection molding

Project leader: Prof. Dr.-Ing. Gerhard Ziegmann and Prof. Dr.-Ing. Joachim Deubener

Funding period: 2010 - 2012 Funding body: DFG, Bonn Funding code: -

Contact: Dipl.-Ing. Randolf Hoffmann and Dipl.-Geow. Simon Striepe

Due to their good chemical and thermal resistance, their optical properties, the ability to be sterilized as well as their biocompatibility and the possibility to be easily cleaned, microstructured glass devices are found in many applications. Nevertheless, current production techniques of such glass devices are not suitable for realizing low-cost mass production. Therefore, it is necessary to find new manufacturing options to increase the cost efficiency of the production of microstructured glass components while ensuring high precision manufacturing with short cycle times.

The aim of the project is to systematically investigate the processability of glasses in micro injection molding. To this end, an experimental micro injection molding system will be developed and built on a laboratory scale. In addition, the thermodynamic properties of chemically resistant phosphate glasses with a low glass transition temperature will be investigated with particular reference to the ambient conditions prevailing in the microinjection molding process. Furthermore, the effects of the mold material and its surface finish on the flowability of the glass melt in the microcavities and novel methods of manufacturing these cavities are investigated. A mathematical model will be developed to simulate the flow of the melt in the microcavities. Finally, the process parameters affecting quality and methods for quality control (optical and mechanical properties, residual stresses, surface roughness, geometry and dimensional accuracy) will be identified.