Composite Mold Element for Microarray Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing mold elements for microarrays, such as injection molding and laser processes, are time-consuming and costly, especially for producing high quantities of microarrays with microneedles that require precise and cost-effective mold production.
Innovation Solution
A method involving a composite mold element with a planar base element and an auxiliary element, where the base element is penetrated to form continuous mold openings extending through both sides, allowing for efficient filling from both sides and reducing production time and costs by combining the processes of manufacturing and opening the mold in a single step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection molding is used to manufacture silicone molds with recesses, then the molds can be produced, but the process is time-consuming and costly for high quantity production
Solution Approach 1:
The mold element is divided into a base element and a separate auxiliary element. The base element is first penetrated to form mold openings, then the auxiliary element is applied to fill and complete the mold structure. This segmentation allows for more efficient manufacturing compared to traditional injection molding of complete molds.
Solution Approach 2:
The base element is penetrated to form mold openings before the auxiliary element is applied. This preliminary action of creating openings in the base element allows for subsequent efficient filling and mold completion, reducing overall production time.
2Productivity
If traditional injection molding is used, then molds can be manufactured, but the cost increases for high quantity production
Solution Approach 1:
By segmenting the mold into a base element and auxiliary element, the manufacturing process becomes more cost-effective for high quantities. The base element can be produced efficiently and then combined with the auxiliary element, reducing the overall cost compared to traditional injection molding of complete molds.
Solution Approach 2:
The base element and auxiliary element are combined to form the complete mold structure. This merging of two simpler components is more cost-effective than manufacturing complex complete molds through traditional injection molding, especially for high quantity production.
3Ease of operation
If mold openings are formed by penetrating the base element, then filling can occur from both sides, but the process complexity increases
Solution Approach 1:
The mold is segmented into a base element with openings and an auxiliary element for filling. This segmentation enables filling from both sides of the base element, improving filling efficiency while the modular nature keeps the overall process manageable despite the added complexity.
Solution Approach 2:
The penetration of the base element creates openings that extend through the thickness dimension, enabling filling from both the front and back sides. This dimensional approach to opening formation improves filling efficiency by utilizing the third dimension (thickness) to create bidirectional access.
Data Source
AI summary
provided is a method for manufacturing a mold element for the production of microarrays, including the following steps: (i) providing a planar base element having a first surface and a second surface opposite the first surface, (ii) providing a planar auxiliary element on the second surface, (iii) penetrating the base element from the first surface in order to form mold openings, and (iv) reversibly or non-reversibly entering the auxiliary element when penetrating the base element. Moreover, a mold element for the production of microarrays, including a planar base element having a first surface a second surface opposite the first surface, a planar auxiliary element arranged on the second surface, and several mold openings extending from the surface of the base element through the second surface of the base element.