Micro Injection Molding of Drug-Loaded Round Window Niche Implants for an Animal Model Using 3D-Printed Molds

A novel approach for the long-term medical treatment of the inner ear is the diffusion of drugs through the round window membrane from a patient-individualized, drug-eluting implant, which is inserted in the middle ear. In this study, drug-loaded (10 wt% Dexamethasone) guinea pig round window niche implants (GP-RNIs, ~1.30 mm × 0.95 mm × 0.60 mm) were manufactured with high precision via micro injection molding (µIM, T_mold = 160 °C, crosslinking time of 120 s). Each implant has a handle (~3.00 mm × 1.00 mm × 0.30 mm) that can be used to hold the implant. A medical-grade silicone elastomer was used as implant material. Molds for µIM were 3D printed from a commercially available resin (T_G = 84 °C) via a high-resolution DLP process (xy resolution of 32 µm, z resolution of 10 µm, 3D printing time of about 6 h). Drug release, biocompatibility, and bioefficacy of the GP-RNIs were investigated in vitro. GP-RNIs could be successfully produced. The wear of the molds due to thermal stress was observed. However, the molds are suitable for single use in the µIM process. About 10% of the drug load (8.2 ± 0.6 µg) was released after 6 weeks (medium: isotonic saline). The implants showed high biocompatibility over 28 days (lowest cell viability ~80%). Moreover, we found anti-inflammatory effects over 28 days in a TNF-α-reduction test. These results are promising for the development of long-term drug-releasing implants for human inner ear therapy.

Wetting Characteristics of Laser-Ablated Hierarchical Textures Replicated by Micro Injection Molding

Texturing can be used to functionalize the surface of plastic parts and, in particular, to modify the interaction with fluids. Wetting functionalization can be used for microfluidics, medical devices, scaffolds, and more. In this research, hierarchical textures were generated on steel mold inserts using femtosecond laser ablation to transfer on plastic parts surface via injection molding. Different textures were designed to study the effects of various hierarchical geometries on the wetting behavior. The textures are designed to create wetting functionalization while avoiding high aspect ratio features, which are complex to replicate and difficult to manufacture at scale. Nano-scale ripples were generated over the micro-scale texture by creating laser-induced periodic surface structures. The textured molds were then replicated by micro-injection molding using polypropylene and poly(methyl methacrylate). The static wetting behavior was investigated on steel inserts and molded parts and compared to the theoretical values obtained from the Cassie-Baxter and Wenzel models. The experimental results showed correlations between texture design, injection molding replication, and wetting properties. The wetting behavior on the polypropylene parts followed the Cassie-Baxter model, while for PMMA, a composite wetting state of Cassie-Baxter and Wenzel was observed.

Effects of Cavity Thickness and Mold Surface Roughness on the Polymer Flow during Micro Injection Molding

In micro injection molding, the cavity thickness and surface roughness are the main effects factors of polymer flow in the die designing and affect the quality of molded products significantly. In this study, the effects of cavity thickness and roughness of cavity surface were investigated mainly on polymer flow during molding and on the roughness of molded products. The parts were molded in the cavities with the thickness from 0.05 mm to 0.25 mm and surface roughness from R_a = 46.55 nm to R_a = 462.57 nm, respectively. The filling integrities and roughness replication ratio of molded parts were used to evaluate the statements of polymer flow and microstructure replication during micro injection molding, respectively. The results showed that the filling integrity changing trends in the thinner cavities were obviously different or even opposite to those in the thicker cavities with the changing of cavity surface roughness instead of single trend in the conventional studies. For each cavity surface roughness, the filling integrity showed an upward trend with the increasing cavity thickness. In different cavity thickness, the maximum gap of filling integrity was 23.76 mm, reaching 544.94% from 0.05 mm to 0.25 mm. Additionally, the surface roughness ratio was slightly smaller than one before, reaching the polymer surface roughness limit around R_a = 71.27 nm, which was decided by the nature of the polymer itself. This study proposed the references for the design and fabrication of mold cavities and parts, and saved time and cost in the actual product manufacturing.

Quality Definition in Micro Injection Molding Process by Means of Surface Characterization Parameters

Quality evaluation of micro injection molded products is a complex task, in particular when instruments basing on contact methods are used and issues in measurements could arise due to the contact tool dimension not fitting well with extremely narrow features. Therefore, in these cases, optical methods may be preferred for the evaluation of molded products’ dimensions and surface quality, especially for parts devoted to applications requiring functional purposes. In this context, the present paper proposes the use of surface parameters as a quality index for the evaluation of both the micro injection molding process and the resulting products. To this aim, two experimental procedures were implemented to allow for: (i) the evaluation of the most suitable surface parameters identified in relation to the process parameters; (ii) comparisons of the surface parameters findings with those obtained by classic dimensional quantity via a designed experimental plan (DoE). The results show that the surface parameters, evaluated in critical areas of the components, can ensure reliable estimates for the surface quality of the molded parts and can be preferred in comparison to linear measurements.

Molecular Insights into the Wall Slip Behavior of Pseudoplastic Polymer Melt in Nanochannels during Micro Injection Molding

Wall slip directly affects the molding quality of plastic parts by influencing the stability of the filling flow field during micro injection molding. The accurate modeling of wall slip in nanochannels has been a great challenge for pseudoplastic polymer melts. Here, an effective modeling method for polymer melt flow in nanochannels based on united-atom molecular dynamics simulations is presented. The effects of driving forces and wall–fluid interactions on the behavior of polyethylene melt under Poiseuille flow conditions were investigated by characterizing the slip velocity, dynamics information of the flow process, and spatial configuration parameters of molecular chains. The results indicated that the united-atom molecular dynamics model could better describe the pseudoplastic behavior in nanochannels than the commonly used finitely extensible nonlinear elastic (FENE) model. It was found that the slip velocity could be increased with increasing driving force and show completely opposite variation trends under different orders of magnitude of the wall–fluid interactions. The influence mechanism was interpreted by the density distribution and molecular chain structure parameters, including disentanglement and orientation, which also coincides with the change in the radius of gyration.

Numerical Simulation on the Acoustic Streaming Driven Mixing in Ultrasonic Plasticizing of Thermoplastic Polymers

The acoustic melt stream velocity field, total force, and trajectory of fluorescent particles in the plasticizing chamber were analyzed using finite element simulation to investigate the acoustic streaming and mixing characteristics in ultrasonic plasticization micro-injection molding (UPMIM). The fluorescence intensity of ultrasonic plasticized samples containing thermoplastic polymer powders and fluorescent particles was used to determine the correlation between UPMIM process parameters and melt mixing characteristics. The results confirm that the acoustic streaming driven mixing occurs in ultrasonic plasticization and could provide similar shear stirring performance as the screw in traditional extrusion/injection molding. It was found that ultrasonic vibrations can cause several melt vortices to develop in the plasticizing chamber, with the melt rotating around the center of the vortex. With increasing ultrasonic amplitude, the melt stream velocity was shown to increase while retaining the trace, which could be altered by modulating other parameters. The fluorescent particles are subjected to a two-order-of-magnitude stronger Stokes drag force than the acoustic radiation force. The average fluorescence intensity was found to be adversely related to the distance from the sonotrodes' end surface, and fluorescence particles were more equally distributed at higher parameter levels.

New Considerations on the Determination of the Apparent Shear Viscosity of Polymer Melt with Micro Capillary Dies

Capillary rheometers have been widely used for the rheological measurement of polymer melts. However, when micro capillary dies are used, the results are usually neither accurate nor consistent, even under the same measurement conditions. In this work, theoretical modeling and experimental studies were conducted for a more profound understanding of the mechanism by which the initial and boundary conditions influence the inaccuracy in the apparent shear viscosity determination with micro capillary dies (diameters: 500 μm, 200 μm, 100 μm). The results indicate that the amount of polymer initially in the barrel, the pre-compaction pressure and the capillary die diameter have a significant influence on the development of the micro scale inlet pressure, which directly determines the accuracy of the measurement at low and medium shear rates. The varying melt compressibility was confirmed to be the main factor directly related to the inaccuracy in the micro scale apparent shear viscosity determination. It is suggested that measures such as reducing the amount of polymer initially in the barrel and increasing the pre-compaction pressure could be used to reduce the measurement inaccuracy.

Multi-Scale Simulation of Injection Molding Process with Micro-Features Replication: Relevance of Rheological Behaviour and Crystallization

The possibility of tailoring key surface properties through the injection molding process makes it intriguing from the perspective of sustainability enhancement. The surface properties depend on the replication accuracy of micro and nanostructures on moldings; such an accuracy is enhanced with cavity temperature. The simulation of the injection molding process is very challenging in the presence of micro and nanostructures on the cavity surface; this does not allow for the neglect of phenomena generally considered not to influence the overall process. In this paper, a multiscale approach was proposed: in the first step, the simulation of the overall process was conducted without considering the presence of the microstructure; in the second step the outputs of the first step were used as an input to simulate the replication of the microfeature. To this purpose, a lubrication approximation was adopted, and the contribution of the trapped air, which slows down the polymer advancement, was accounted for. A modification of the viscosity equation was also proposed to describe the rheological behavior of isotactic polypropylene at very low temperatures. Concerning the microcavity filling simulation, the modification of the viscosity description at low temperatures consistently describes the process, in terms of polymer solidification. Concerning the replication accuracy, it increases with the cavity surface temperature, consistently with the experimental observations.

Experimental Investigation and Molecular Dynamics Simulation on the Anti-Adhesion Behavior of Alkanethiols on Nickel Insert in Micro Injection Molding

Due to the adhesion between the polymer melt and nickel (Ni) mold insert in the micro injection molding process, deformation defects frequently occur when the microstructures are demolded from the insert. In this study, self-assembled alkanethiols were applied to modify the surface of Ni mold insert to reduce its surface energy. Experimental trials were undertaken to explore the effect of alkanethiols coating on the replication quality. After that, molecular dynamics (MD) simulation was then used to investigate the adhesion behavior between the self-assembled coating and polypropylene (PP) by establishing three different types of alkanethiol material. The interaction energy, the potential energy change and radial distribution function were calculated to study the anti-adhesion mechanism. Experimental results show that all the three coatings can effectively decrease the adhesion and therefore promote the replication fidelity. It is demonstrated in MD simulation that the adhesion mainly comes from the van der Waals (vdW) force at the interface. The arrangement of sulfur atom on the Ni surface results in different absorbing behaviors. Compared with that of the PP–Ni interface, the interfacial energy and adhesion work after surface treatment is significantly reduced.

Micro Injection Molding of Thin Cavities Using Stereolithography for Mold Fabrication

At the present time, there is a growing interest in additive manufacturing (AM) technologies and their integration into current process chains. In particular, the implementation of AM for tool production in micro injection molding (µ-IM), a well-established process, could introduce many advantages. First of all, AM could avoid the need for the time-consuming and expensive fabrication of molds for small series of customized products. In this work, the feasibility, quality, and reliability of an AM/µ-IM process chain were evaluated by designing and fabricating mold inserts for µ-IM by stereolithography (SLA) technology; the mold inserts were characterized and tested experimentally. The selected geometry is composed of four thin cavities: This particular feature represents an actual challenge for both the SLA and µ-IM perspective due to the large surface-to-volume ratio of the cavity. Two different materials were used for the mold fabrication, showing sharply different performance in terms of endurance limit and cavity degradation. The obtained results confirm that the µ-IM process, exploiting an SLA fabricated mold insert, is feasible but requires great accuracy in material choice, mold design, fabrication, and assembly.

Characterization of Stereolithography Printed Soft Tooling for Micro Injection Molding

The use of microfeature-enabled devices, such as microfluidic platforms and anti-fouling surfaces, has grown in both potential and application in recent years. Injection molding is an attractive method of manufacturing these devices due to its excellent process throughput and commodity-priced raw materials. Still, the manufacture of micro-structured tooling remains a slow and expensive endeavor. This work investigated the feasibility of utilizing additive manufacturing, specifically a Digital Light Processing (DLP)-based inverted stereolithography process, to produce thermoset polymer-based tooling for micro injection molding. Inserts were created with an array of 100-μm wide micro-features, having different heights and thus aspect ratios. These inserts were molded with high flow polypropylene to investigate print process resolution capabilities, channel replication abilities, and insert wear and longevity. Samples were characterized using contact profilometry as well as optical and scanning electron microscopies. Overall, the inserts exhibited a maximum lifetime of 78 molding cycles and failed by cracking of the entire insert. Damage was observed for the higher aspect ratio features but not the lower aspect ratio features. The effect of the tool material on mold temperature distribution was modeled to analyze the impact of processing and mold design.

Fabrication of Micro-Structured LED Diffusion Plate Using Efficient Micro Injection Molding and Micro-Ground Mold Core

In this paper, a new style of micro-structured LED (light-emitting diode) diffusion plate was developed using a highly efficient and precise hybrid processing method combined with micro injection molding and micro-grinding technology to realize mass production and low-cost manufacturing of LED lamps with excellent lighting performance. Firstly, the micro-structured mold core with controllable shape accuracy and surface quality was machined by the precision trued V-tip grinding wheel. Then, the micro-structured LED diffusion plate was rapidly fabricated by the micro injection molding technology. Finally, the influences of micro injection molding process parameters on the illumination of the micro-structured diffusion plate were investigated. The simulated optical results show that the illumination of the micro-structured diffusion plate can achieve a maximum value when the V-groove depth and V-groove angle are designed to be 300 μm and 60°, respectively. The experimental results indicate that the developed micro-structured diffusion plate may improve the illumination by about 40.82% compared with the traditional diffusion plate. The prediction accuracy of the designed light efficiency simulation method was about 90.33%.

Fabrication of Micro-Structured Polymer by Micro Injection Molding Based on Precise Micro-Ground Mold Core

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.

Replication of Overmolded Orthopedic Implants with a Functionalized Thin Layer of Biodegradable Polymer

The present paper reports on the development of a biodegradable overmolded orthopedic implant: a metal bone fixing screw, which has been overmolded with a functionalized thin layer of biodegradable polymer to enhance cell adhesion during the healing process. The main challenges were to integrate precise, high-throughput and repeatable solutions to achieve a thin, defect-free structured polymer layer and to ensure a high and consistent implant quality. The work carried out entailed determining proper materials (Purasorb PDLG 5010) for the biodegradable overmolding layer and its economical substitute (NaKu PLA 100HF) to be used during initial tool and process development, designing the surface structure of the overmolded polymer layer, development of injection molding tools, as well as feeding and handling procedures. The injection overmolding process of Purasorb PDLG 5010 polymer was controlled, and the process parameters were optimized. In particular, the dominant process parameters for the overmolding, namely injection pressure, barrel temperature and mold temperature, were experimentally examined using a circumscribed three-factor central composite design and two quality marks; overmolding roughness and mass of polymer. The analysis of the experimental results shows that the mass of the overmolding is not feasible for use as the quality mark. However, the optimal parameters for the overmolding of a metallic implant screw with a thin, micro-structured polymer layer with a predefined roughness of the surface texture have been identified successfully.

Numerical Simulation and Experimental Investigation of the Viscoelastic Heating Mechanism in Ultrasonic Plasticizing of Amorphous Polymers for Micro Injection Molding

Ultrasonic plasticizing of polymers for micro-injection molding has been proposed and studied for its unique potential in materials and energy-saving. In our previous work, we have demonstrated the characteristics of the interfacial friction heating mechanism in ultrasonic plasticizing of polymer granulates. In this paper, the other important heating mechanism in ultrasonic plasticizing, i.e., viscoelastic heating for amorphous polymer, was studied by both theoretical modeling and experimentation. The influence mechanism of several parameters, such as the initial temperature of the polymer, the ultrasonic frequency, and the ultrasonic amplitude, was investigated. The results from both numerical simulation and experimentation indicate that the heat generation rate of viscoelastic heating can be significantly influenced by the initial temperature of polymer. The glass transition temperature was found to be a significant shifting point in viscoelastic heating. The heat generation rate is relatively low at the beginning and can have a steep increase after reaching glass transition temperature. In comparison with the ultrasonic frequency, the ultrasonic amplitude has much greater influence on the heat generation rate. In light of the quantitative difference in the viscoelastic heating rate, the limitation of the numerical simulation was discussed in the aspect of the assumptions and the applied mathematical models.