• Design & Manufacturing
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• v.16 no.3
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• pp.58-65
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• 2022

Micro-fluidic chip has been fabricated by lithography process on silicon or glass wafer, casting using PDMS, injection molding of thermoplastics or 3D printing, etc. Among these processes, 3D printing can fabricate micro-fluidic chip directly from the design without master or template for fluidic channel fabricated previously. Due to this direct printing, 3D printing provides very fast and economical method for prototyping micro-fluidic chip comparing to conventional fabrication process such as lithography, PDMS casting or injection molding. Although 3D printing is now used more extensively due to this fast and cheap process done automatically by single printing machine, there are some issues on accuracy or surface characteristics, etc. The accuracy of the shape and size of the micro-channel is limited by the resolution of the printing and printing direction or layering direction in case of SLM type of 3D printing using UV curable resin. In this study, the printing direction and thickness of each printing layer are investigated to see the effect on the size, shape and surface of the micro-channel. A set of micro-channels with different size was designed and arrayed orthogonal. Micro-fluidic chips are 3D printed in different directions to the micro-channel, orthogonal, parallel, or skewed. The shape of the cross-section of the micro-channel and the surface of the micro-channel are photographed using optical microscopy. From a series of experiments, an optimal printing direction and process conditions are investigated for 3D printing of micro-fluidic chip.

• Design & Manufacturing
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• v.17 no.2
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• pp.55-61
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• 2023

With femtosecond (fs) laser pulse irradiation on metals, various types of nano- and micro-scale structures can be naturally induced at the surface through laser-matter interaction. Two notable structures are laser-induced periodic surface structures (LIPSSs) and cone/spike structures, which are known to significantly modify the optical and physical properties of metal surfaces. In this work, we irradiate fs laser pulses onto various types of metals, cold-rolled steel, pickled & oiled steel, Fe-18Cr-8Ni alloy, Zn-Mg-Al alloy coated steel, and pure Cu which can be useful for precise molding and imprinting processes, and adjust the morphological profiles of LIPSSs and cone/spike structures for clear structural coloration and a larger range of surface wettability control, respectively, by changing the fluence of laser and the speed of raster scan. The periods of LIPSSs on metals used in our experiments are nearly independent of laser fluence. Accordingly, the structural coloration of the surface with LIPSSs can be optimized with the morphological profile of LIPSSs, controlled only by the speed of the raster scan once the laser fluence is determined for each metal sample. However, different from LIPSSs, we demonstrate that the morphological profiles of the cone/spike structures, including their size, shape, and density, can be manipulated with both the laser fluence and the raster scan speed to increase a change in the contact angle. By injection molding and imprinting processes, it is expected that fs laser-induced surface structures on metals can be replicated to the plastic surfaces and potentially beneficial to control the optical and wetting properties of the surface of injection molded and imprinted products.

• Journal of Powder Materials
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• v.11 no.6 s.47
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• pp.472-476
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• 2004

The Fe-Ni compact bodies were fabricated using Fe-Ni mixed powders with 50 nm in diameter by injection molding process. The relationship between microstructure and material properties was characterized with respect to the volume ratio of powder/binder and sintering temperature with SEM and TEM. In the compact body having the volume percent ratio of 45(Fe-Ni) : 55(binder), which was sintered at $900^{\circ}C$ the values of relative density and hardness were low about 97.7% and 277.1 Hv, respectively. Using the composition of 50(Fe Ni) : 50(binder) and sintered at $900^{\circ}C$, the values of relative density and hardness were 98.5%, 294.4 Hv, respec-tively. The grain size of sintered bodies strongly depended on the sintering temperature. In both samples sintered at $600^{\circ}C$ and $900^{\circ}C$, the average grain sizes were about 150 nm and 500 nm in diameter, respectively.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.10a
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• pp.698-701
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• 2005

We have investigated experimentally a nano patterning using electron beam lithography for the nickel stamper fabrication. Recently, DVD and Blu-ray disk(BD) have nano-scale patterns in order to increase the storage density. Specially, BD has 100nm-scale patterns which are generally fabricated by electron beam lithography. In this paper, we found optimum condition of electron-beam lithography for 100nm-scale patterning. We controlled various conditions of EHP(acceleration voltage), beam current, dose and aperture size in order to obtain optimum conditions. We used 100nm-thick PMMA layer on a silicon wafer as photoresist. We found that EHP was the most dominant factor in electron-beam lithography.

• Korean Journal of Materials Research
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• v.14 no.11
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• pp.795-801
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• 2004

The injection molded Fe sintered bodies were fabricated using two kinds of Fe powders haying 50 nm and $3\sim5{\mu}m$ in diameter. In the using of Fe powder having 50 nm in diameter, the comparatively dense bodies ($94\sim97\%$) were obtained even at low sintering temperature ($600\sim700^{\circ}C$), while in the sintered bodies ($1000^{\circ}C$) using $3\sim5{\mu}m$ Fe powder, their relative densities showed low values about $93\%$, although they were strongly depend on the sintering temperature and volume ratio of Fe powder and binder. In the sintered bodies using of 50 nm Fe powders, the volume shrinkage and grain size increased as the sintering temperature increased, but the values of hardness decreased. In the sample sintered at $650^{\circ}C$, the values of relative density, volume shrinkage and grain size were $96\%,\;37\%\;and\;0.97{\mu}n$, respectively and the minimum value of wear depth was obtained due to combination of fine grain and comparatively high density.

• Proceedings of the KAIS Fall Conference
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• 2003.06a
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• pp.356-358
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• 2003

본 연구에서는 일반사출과 MmSH방식 두 가지의 사출성형공정을 이용하여 나노 패턴 구조물을 제작하였다. 성형품에 나타난 나노패턴의 진사성은 MmSH방식을 이용한 PC 성형품에서 가장 우수했다. 일반사출공정에서 HIPS로 제작된 성형품은 나노패턴의 전사가 잘 형성되었고, PC의 경우 전사가 잘 이루어지지 않았다. 연구 결과 수지의 유동성이 좋고, 금형표면 온도가 높을수록 나노패턴의 전사성은 향상됨을 알 수 있었다.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.18 no.6
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• pp.697-701
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• 2009

A simple method for the fabrication of porous nano-master for the anti-reflection effect on the transparent substrates is presented. In the conventional fabrication methods for antireflective surface, coating method using materials with low refractive index has usually been used. However, it is required to have a high cost and long processing time for mass production. In this paper, we developed a porous nano-master with anti-reflective surface for the molding stamper of the injection mold, hot embossing and UV imprinting by using the aluminum anodizing process. Through two-step anodizing and etching processes, a porous nano-master with anti-reflective surface was fabricated at the large area. Pattern size Pore diameter and inter-pore distance are about 130nm and 200nm, respectively. In order to replicate anti-reflective structure, hot embossing process was performed by varying the processing parameters such as temperature, pressure and embossing time etc. Finally, antireflective surface can be successfully obtained after etching process to remove selectively silicon layer of AAO master.

• IE interfaces
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• v.25 no.1
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• pp.40-51
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• 2012

Today, many manufacturing companies realize that collaboration is crucial for their survival. Especially, in the perspective of quality, the importance of collaboration is emphasized because economic loss increases exponentially while defective parts go through the process in supply chain. However, the manufacturing companies are facing two main difficulties in implementing collaborative relationships with their suppliers. First, it is difficult for the suppliers to produce reliable products due to their obsolete facilities. The problem gets worse for second- or third-tire vendors. Second, the companies experience the lack of universally understandable set of terminology and effective methodologies for knowledge representation. Ontology is one of the best approaches to expressing and processing a domain knowledge. In this paper, we propose the manufacturing ontology-based quality prediction framework to represent and share the knowledge of industrial environment and to predict product quality in manufacturing processes. In addition, we develop the ontology-based quality prediction system based on the proposed framework. We carried out a series of experiments for an injection molding process at an automotive part supplier. The experimental results demonstrated that the proposed framework and system can be successfully applicable in manufacturing industry.

• Journal of Powder Materials
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• v.11 no.6 s.47
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• pp.528-534
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• 2004

Using the nano Fe powders having 50 nm in diameter, Fe compact bodies were fabricated by injec-tion molding process. The relationship between microstructure and material properties depending on the volume ratio of powder/binder and sintering temperature were characterized by SEM, TEM techniques. In the compact body with the volume percentage ratio of 45(Fe powder) : 55(binder), which was sintered at $700^{\circ}C,$ the relative density was about $97{\%},$ and the values of volume shrinkage and hardness were about $66.3{\%}$ and 242.0 Hv, respec-tively. Using the composition of 50(Fe powder) : 50(binder) and sintered at $700^{\circ}C,$ the values of relative density, volume shrinkage and hardness of Fe sintered bodies were $73.3{\%},\;47.6{\%}$ and 152.8 Hv, respectively. They showed brittle fracture mode due to the porous and fine microstructure.

• Korean Journal of Materials Research
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• v.20 no.11
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• pp.570-574
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• 2010

A diamond-like carbon (DLC) film deposited on a WC disk was investigated to improve disk wear resistance for injection molding of zirconia optical ferrule. The deposition of DLC films was performed using the filtered vacuum arc ion plating (FV-AIP) system with a graphite target. The coating processing was controlled with different deposition times and the other conditions for coating, such as input power, working pressure, substrate temperature, gas flow, and bias voltage, were fixed. The coating layers of DLC were characterized using FE-SEM, AFM, and Raman spectrometry; the mechanical properties were investigated with a scratch tester and a nano-indenter. The friction coefficient of the DLC coated on the WC was obtained using a pin-on-disk, according to the ASTM G163-99. The thickness of DLC films coated for 20 min. and 60 min. was about 750 nm and 300 nm, respectively. The surface roughness of DLC films coated for 60 min. was 5.9 nm. The Raman spectrum revealed that the G peak of DLC film was composed of $sp^3$ amorphous carbon bonds. The critical load (Lc) of DLC film obtained with the scratch tester was 14.6 N. The hardness and elastic modulus of DLC measured with the nano-indenter were 36.9 GPa and 585.5 GPa, respectively. The friction coefficient of DLC coated on WC decreased from 0.2 to 0.01. The wear property of DLC coated on WC was enhanced by a factor of 20.