Evaluation of mold roughness influence on injected thin micro-cavities

Due to its ability to produce low-cost and high repeatable micro-polymeric parts, micro-injection molding is emerging as one of the most promising enabling technologies in many different fields. When approaching the micro-scale, different issues related to the process should be addressed, especially as the thickness of the cavities becomes very thin. In particular, the mold roughness affects the surface quality of the micro-components produced, like in macro-molding, but this could also encompass the complete filling of the parts. The main objective of the present paper is to evaluate the roughness influence of the mold on the non-Newtonian fluid flow during the micro-injection process in thin micro-cavities where the mold surface condition could affect the process due to the phenomena neglected in macro- or mesoscale as less important boundary conditions. The part design was properly conceived in order to neglect the effect of dimensions and geometry and to highlight the roughness contribution during the filling phase. The experimentation was performed using cavities with different roughness values and decreasing depths from 200 to 50 μm, considerably lower than 250 μm found in literature and manufactured by the micro-electrical discharge machining (μ-EDM). The results of the experiments are discussed and show that cavity-surface roughness affects the process as the molding scale is decreased. In particular, in thin cavities, higher surface roughness promotes the filling of component.