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.

Our nanoinjection molding technology can achieve a pattern structure of size smaller than 20 microns and is suitable for mass production. Nanoinjection molding technology combines elements of nanoimprinting with injection molding, to create three-dimensional (3D) free-form plastic products, with a micro and nanometer-scaled patterned surface.

Nanoinjection molding allows the creation of micro and nanometer-scale structures of resolutions as high as 0.5 micron to be molded directly. As a result, additional surface optical and mechanical functionalities can be added to the plastic molded products, for lab-on-a-chip and optical components applications.

 

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 highresolution inserts are made of hybrid nickel-steel and nickel shimThe polymer material used in nanoinjection molding are PC, 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 the consumer wearable and biomedical sector. It can value adds an existing product by imparting surface functionalities.

Nanoinjection molding value-proposition

Price competitive

Integrating multiple functionalities on molded plastic. Plastic is relatively lower in cost to 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 nanometrescale features can be design 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

Process flow for nanoinjection molding

Mold fabrication
  • Master Mold fabrication
  • Hybrid Nickel-Steel insert fabrication
Nanoinjection molding
  • Mass production of the plastic chip via injection compression molding
Laser micromachining
  • Individual molded chips are laser trim to exact dimension.
Coating
  • Molded chips are coated with diamond-like-carbon (DLC) coating for scratch and chemical resistance.
Final inspection
  • 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

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