Yes / The prevalence of micromoulded components has steadily increased over recent years. The production of such components is extremely sensitive to a number of variables that may potentially lead to significant changes in the surface geometry, often regarded as a crucial determinant of the product¿s functionality and quality. So far, traditional large-scale quality assessment techniques have been used in micromoulding. However, these techniques are not entirely suitable for small scales . Techniques such as Atomic Force Mi- croscopy (AFM) or White Light Interferometry (WLI) have been used for obtaining full three-dimensional profiles of micromoulded components, pro- ducing large data sets that are very difficult to manage. This work presents a method of characterizing surface features of micro and nano scale based on the use of the Biharmonic equation as means of describing surface profiles whilst guaranteeing tangential (C1) continuity. Thus, the problem of rep- resenting surface features of micromoulded components from massive point clouds is transformed into a boundary-value problem, reducing the amount of data required to describe any given surface feature.The boundary conditions needed for finding a particular solution to the Biharmonic equation are extracted from the data set and the coefficients associated with a suitable analytic solution are used to describe key design parameters or geometric properties of a surface feature. Moreover, the expressions found for describ- ing key design parameters in terms of the analytic solution to the Biharmonic equation may lead to a more suitable quality assessment technique for mi- cromoulding than the criteria currently used. In summary this technique provides a means for compressing point clouds representing surface features whilst providing an analytic description of such features. The work is applicable to many other instances where surface topography is in need of efficient representation.

no / The prevalence of micromoulded components has steadily increased over recent years. The production of such components is extremely sensitive to a number of variables that may potentially lead to significant changes in the surface geometry, often regarded as a crucial determinant of the product¿s functionality and quality. So far, traditional large-scale quality assessment techniques have been used in micromoulding. However, these techniques are not entirely suitable for small scales . Techniques such as Atomic Force Mi- croscopy (AFM) or White Light Interferometry (WLI) have been used for obtaining full three-dimensional profiles of micromoulded components, pro- ducing large data sets that are very difficult to manage. This work presents a method of characterizing surface features of micro and nano scale based on the use of the Biharmonic equation as means of describing surface profiles whilst guaranteeing tangential (C1) continuity. Thus, the problem of rep- resenting surface features of micromoulded components from massive point clouds is transformed into a boundary-value problem, reducing the amount of data required to describe any given surface feature.The boundary condi- tions needed for finding a particular solution to the Biharmonic equation are extracted from the data set and the coefficients associated with a suitable analytic solution are used to describe key design parameters or geometric properties of a surface feature. Moreover, the expressions found for describ- ing key design parameters in terms of the analytic solution to the Biharmonic equation may lead to a more suitable quality assessment technique for micromoulding than the criteria currently used. In summary this technique provides a means for compressing point clouds representing surface features whilst providing an analytic description of such features. The work is applicable to many other instances where surface topography is in need of efficient representation. / EPSRC

No / The growth in Micro Electro-Mechanical Systems (MEMS) and demand for functional devices at smaller and smaller length scales has placed increasing demands on industry for product miniaturisation. Consequently, the micro-injection moulding (micromoulding) technology has evolved for the mass production of minute, intricate, polymer and composite components. Although there has been significant growth in the technology, there is little understanding of the effects of the process dynamics on product properties. This paper presents details of a programme of work conducted within these laboratories with the objectives of enhancing the understanding of polymer processing-property interaction. More particularly, the effects of microscale processing on the rheological, mechanical and tribological properties of engineering and commodity polymers, nanocomposites, metal and ceramic injection moulded feedstock and biomaterials are being explored. Simple analysis reveals that process conditions are potentially more severe on melts than those encountered during conventional moulding. High shear and rapid cooling rates combined with a large surface area to volume ratio may have a much greater influence over the resultant properties of a micromoulded product. A Battenfeld Microsystem50 micromoulding machine has been instrumented with a variety of sensors and data acquisition equipment, producing process data for a number of different cavity geometries. A novel microinjection compounding (MIC) machine has also been developed minimising the process stages and reducing material exposure to excessive residence times. This paper gives details of the effects of micromoulding process conditions on component surface morphology and mechanical properties measured using SEM, atomic force microscopy and nano-indentation techniques.

No / Advances in micromoulding technology are leading to complex,net-shape products having sub-milligramme masses with micro-scale surface features in a range of polymer and nano-composite materials.For such small components subjected to the extreme stress,strain-rate and temperature gradients encountered in the micromoulding process,detailed process monitoring is desirable to highlight variations in moulding conditions and assist in creating a viable manufacturing process with acceptable quality products.This paper covers the implementation of a suite of sensors on a commercial micromoulding machine and detailed computer monitoring during processing of a polyacetal component over a range of processing conditions.The results determined that cavity pressure curve integral data provides the most sensitive factor for characterisation of a moulding process of a 0.34 mm~3(0.49 mg)product.The repeatability of the process is directly compared with that of a 15.6mm~3(22.2 mg)product and shown to beinferior.DSC measurements of the whole products indicated little variation in average crystallinity of the products manufactured over a mould temperature range of 30 to 130deg C.

yes / This work outlines a novel approach for determining thermal contact resistance (TCR) in micromoulding. The proposed technique aims to produce TCR predictions with known confidence values and combines experimental evidence (temperature fields and contact angle measurements) with various mathematical modelling procedures (parametric representation of surfaces, finite element analysis and stochastic processes). Here, emphasis is made on the mathematical aspects of the project. In particular, we focus on the description of the parametric surface representation technique based on the use of partial differential equations, known as the PDE method, which will be responsible for characterizing and compressing micro features in either moulds or surface tools. / EPSRC

Yes / Industry-standard quality management systems such as Six Sigma and emerging Industry 4.0 compliant production processes demonstrate the importance of in-line condition monitoring of manufacturing methods for achieving the highest levels of product quality. Measurement data collected as the process is running can inform the operator about unexpected changes in machine operation or raw materials that could negatively impact production; and offer an opportunity for a process control intervention to stabilise production. However, micro-manufacturing production lines can pose a challenging environment for deploying such systems, since processing events can occur extremely rapidly and in harsh environments. Moreover, the small scale of micro-nano featured components can make sensor installation even more problematic. Recently, ultrasonic micromoulding has drawn attention in niche markets due to its unique advantages for processing thermoplastics as a new micro-manufacturing technology. The process differs from conventional moulding significantly by eliminating the need for a plasticising screw and using direct application of ultrasonic energy to melt the polymer. This offers numerous benefits such as decrease in energy usage, moulding at lower pressures, easier cleaning, and reduced material residence times, the latter which could be beneficial for pharma-grade polymers or polymers with active ingredients. However, very little work has been reported attempting to monitor the process using in-line measurements. This work aims to evaluate the characteristics of the ultrasonic micromoulding process for microinjection moulding of a microneedle array using a range of sensor technologies including: data recorded by the machine controller; a high-speed thermal camera and a cavity pressure transducer. The data has captured the highly dynamic process environment with a high degree of accuracy. The relationship between the process data and dimensional quality of the ultrasonically micromoulded products has been quantified and subsequently implemented as a cost-effective in-line quality assurance method. / Horizon 2020, the EU Framework Programme for Research and Innovation (Project ID: 674801). This research has also received funding and support from two other Horizon 2020 projects: HIMALAIA (Grant agreement No. 766871) and Laser4Fun (GA no. 675063)