Shape Memory Mold for Undercut Microstructures
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Solution Overview
Problem
Current manufacturing processes for microstructures struggle to produce complex geometries with undercuts efficiently and cost-effectively, as they often require specialized tools that are costly and limited in geometry, and existing methods like soft imprint and hierarchical molding face issues with wear, temperature resistance, and dimensional stability.
Innovation Solution
A method utilizing shape memory materials in multiple states to create molds with undercuts, allowing for the production of complex geometries by transferring the material through different states to enable demolding and self-healing, using conventional metal molds and avoiding limitations of previous techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional metal molds are used for producing microstructures with undercuts, then manufacturing precision and durability are improved, but the ability to produce complex geometries with undercuts is limited
Solution Approach 1:
The mold insert is made from shape memory material that can dynamically change its geometry between a first configuration (with undercuts for complex microstructures) and a second configuration (without undercuts for easy demolding). This dynamic transformation allows the same mold to produce complex geometries while maintaining manufacturing precision and avoiding the need for separate molds for different geometries.
Solution Approach 2:
The shape memory material changes its physical state based on temperature parameters. When heated above the transformation temperature, the material transforms from austenite to martensite phase, enabling geometry change. This parameter-based control allows precise switching between mold configurations to produce undercuts when needed and facilitate demolding when required.
2Adaptability or versatility
If soft imprint processes are used to produce structures with undercuts, then geometry complexity is improved, but manufacturing precision and durability deteriorate
Solution Approach 1:
The mold insert uses shape memory material that combines the flexibility needed for undercut production with the dimensional stability of metal-like precision. The shape memory material acts as a composite solution, integrating the benefits of soft materials (geometric adaptability) with hard materials (precision and durability) in a single mold component.
Solution Approach 2:
By controlling temperature parameters, the mold insert transitions between soft compliant state (for imprinting undercuts) and rigid precise state (for maintaining dimensional accuracy). This parameter-driven transformation resolves the contradiction between geometry complexity and manufacturing precision.
3Duration of action of stationary object
If elastic mold inserts are used to prevent wear, then durability is improved, but temperature resistance and dimensional stability worsen
Solution Approach 1:
The shape memory material's temperature resistance is enhanced by controlling its transformation temperature to be above the processing temperature range. This allows the mold to withstand high temperatures during microstructure production while maintaining its shape memory functionality, resolving the contradiction between durability and temperature resistance.
4Productivity
If demolding process is used to remove molded bodies, then productivity is improved, but geometry complexity is limited
Solution Approach 1:
The dynamic geometry transformation of the mold insert allows complex undercut structures to be produced and then easily released by transforming to a second configuration. This resolves the contradiction between productivity and geometry complexity by enabling both high-throughput production and complex microstructure fabrication.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the cost-effective and precise production of microstructures with undercuts and self-healing capabilities, maintaining optical properties and structural integrity, overcoming the limitations of previous methods by using shape memory polymers that can revert to original shapes upon temperature changes.
Implementation Method 1
The material comprises at least one shape memory material, wherein the shape memory material is in a first state, wherein the material at least partially fills the receptacle of the molding tool such that it borders on at least one surface of the receptacle; producing a molded body in the receptacle of the molding tool from the material, wherein the shape memory material is in a second state, wherein a shape is impressed into the molded body during the second state; transferring the shape memory material from the second state to a third state, wherein the molded body is deformable during the third state such that demolding of the molded body from the receptacle of the molding tool occurs in the demolding direction; and at least partially restoring the shape of the molded body by transferring the shape memory material from the third state to a fourth state
Implementation Method 2
the shape memory polymer, after thermo-mechanical programming, is capable of undergoing at least one temperature-induced shape transition from a temporary shape to a permanent shape
Data Source
Figure 1a~1d
Figure 2
Figure 3a~3b
AI summary
The present invention relates to a method for producing a moulded body (10), comprising the following steps: a) providing a moulding tool (40), which has at least one receptacle (12) into which at least one material (30) is introduced which comprises at least one shape memory material (31), the shape memory material (31) being present in a first state (111), and the material (30) at least partially filling the receptacle (12) of the moulding tool (40) in such a way that it borders at least one surface of the receptacle (12); b) producing a moulded body (10) from the material (30) in the receptacle (12) of the moulding tool (40), the shape memory material (31) being present in a second state (112), and a shape (11) being imparted to the moulded body (10) during the second state (112); c) transferring the shape memory material (31) into a third state (113), the moulded body (10) being deformable during the third state (113) in such a way that demoulding of the moulded body (10) from the receptacle (12) of the moulding tool (40) takes place; and d) at least partially reproducing the shape (11) of the moulded body (10) by transferring the shape memory material (31) into a fourth state (114), the moulded body (10) at least partially assuming the shape (11) according to step b) again during the fourth state (114).