Rapid prototyping of polymeric microstructures with a UV laser

By laser ablation of Poly-Ether-Ether-Ketone (PEEK), a negative master of the microsystem was produced. This master is then used for hot embossing of a number of polystyrene (PS) parts. A few hundred replications can be made without warping and alteration of the dimensions. The possibility of using ion implantation of the master tool to prolong the lifetime has also been investigated.

For injection moulding, where the pressure and temperature is higher than in hot embossing a positive laser ablated Acrylonitrile-butadien-styrene co-polymer (ABS) structure was used, which subsequently has been electroplated to achieve a negative metal mould insert. The preliminary results have been encouraging.

The total time from concept to realisation of a series of prototypes is 4-5 working days.