NANOINJECTION MOLDING
Injection molding and 3D printing are the standard production technology for plastic parts. However, they are limited to fabricating features and patterns of micron-scale resolution. Winovus’ nanoinjection molding technology can achieve pattern structures smaller than 1 micron. Nanoinjection molding makes it possible to manufacture next-generation plastics lens and medical diagnostics devices.
What is Nanoinjection Molding ?
Nanoinjection molding technology combines nanoimprinting with injection molding to create three-dimensional (3D) free-form plastic with micro and nanometer-scaled patterned surfaces.
Molten polymers are injected under high pressure into a mold cavity with patterned features as small as 0.5 micron. As a result, additional optical and mechanical functionalities can be added to the plastic molded products for lab-on-a-chip and optical components applications. For example, superhydrophobic and anti-reflection functions.
The pivotal element to nanoinjection molding is the mold inserts. We use lithography and electroforming technology to create nanometer-scale patterned inserts. These sub-micron high-resolution inserts are made of hybrid nickel-steel and nickel shim. The polymer material used in nanoinjection molding are PC, PBT, PET, PMMA COC/COP, PS or ABS, depending on the application.
Winovus is a pioneer leader in nanoinjection molding. Our state-of-the-art molding facilities are equipped with automated handling robotics, complete with in-situ and ex-situ inspection and quality control.
Nanoinjection molding enables new product innovation in consumer wearable and medical diagnostics devices through the ability to mold sub-miron features. Harness our nanofabrication technology to take your project from prototype to production.
Nanoinjection molding value-proposition
Price competitive
Integrating multiple functionalities on molded plastic. Plastic is relatively lower in cost than silicon wafer and glass.
Material Flexibility
PC, PMMA COC/COP, PS, ABS, and more.
Rapid production scalability
We control and optimise our injection molding process parameters for high volume manufacturing of 3-D plastic with micro and nanometer-scale structure.
Customized nano-well profiles for specific cell-types
Micro-scale channels or any sub-micron and nanometre–scale features can be designed and manufactured according to customers’ applications.
Examples of nanoinjection molding applications and markets:
- Micro-arrays for genomics
- Microlens array ( MLA)
- Sensors
- Anti-reflective optics
- Microfluidic and Lab-on-a-chip
- Deflective optics and gratings
- Virtual & Augmented Reality optics
- Surface-relief gratings
- Medical equipment & Biotech optics
- Cell-culture plasticware
- Diagnostics instruments
Example of nanoinjection molded microarray specification:
Material Thickness: <1.0 mm
Minimum microhole diameter: 0.5 µm, with an aspect ratio of 1
Positional accuracy: +/-0.5 µm
Taper Angle: 1° to 7°
Chipping: None
Microcracks: None
More on Nanoinjection Molding
What is Nanoinjection Molding?
Process flow for nanoinjection molding
- Master Mold fabrication
- Hybrid Nickel-Steel insert fabrication
- Mass production of the plastic chip via injection compression molding
- Individual molded chips are laser trim to exact dimension.
- Molded chips are coated with diamond-like-carbon (DLC) coating for scratch and chemical resistance.
- All samples are inspected for dimensional stability
Examples of nanoinjection molded features
| Feature Dimension | Aspect Ratio | Applications | |
| Pillar | 500nm to 2um | ≤ 1 | (i)Hydrophobic functionality for the automotive industry |
| (ii) Biomedical plastic cellware | |||
| Hole (well) | 500nm to 2um | ≤ 2 | (i)Hydrophobic functionality for the automotive industry |
| (ii) Biomedical plastic cellware | |||
| (iii) DNA sequencing chip for medical technology | |||
| Grating (Line & Space) | 500nm to 2um | ≤ 2 | (i) Optical grating, diffraction gratings, wire grid polarizers for automotive, Lidar sensors etc |
| (ii) Biomedical plastic cellware | |||
| Cone and valley (moth eye) | 200nm – 300nm | ≤ 1 | (i) Antireflective panel for optics and display technology |
| (ii) OLED screen, plastic lenses, swimming goggles, etc. | |||
| Pyramid structure | 500nm to 2um | ≤ 1 | Lightguide panel |
| Micro Channels | 500nm to 2um | ≤ 1 | Microfluidics chip and lap-on-a-chip and medical diagnostic instruments. |
Pillars
High aspect ratio pillars
Gratings
Wells
Let us know how we can help.
Want to find out more about Winovus’ products and services?
Fill up the form below to enquire with us today.