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Brian Anthony. Nguyen, Khanh H. (Khanh Huy) Massachusetts Institute of Technology. Department of Mechanical Engineering. Massachusetts Institute of Technology. Department of Mechanical Engineering 2014-03-19T15:45:28Z 2014-03-19T15:45:28Z 2013 2013 http://hdl.handle.net/1721.1/85789 871543633 Thesis: M. Eng. in Manufacturing, Massachusetts Institute of Technology, Department of Mechanical Engineering, 2013. Title as it appears in Degrees awarded program, September 17, 2003: Design and analysis of a hot embossing machine and the effects of toolware and accuracy of resin replication of high aspect ratio microfluidic features Cataloged from PDF version of thesis. Includes bibliographical references (pages 132-135). Hot embossing is a growing technology proven to be capable of reproducing micro-scale features on thermoplastics and can be an effective process for rapid prototyping microfluidic devices with high aspect ratio micro features. Advantages of this manufacturing process can include tooling flexibility, fast production time, low capital cost and a vast selection of production materials. A greater understanding on the micro feature transferring capabilities and use limits of tools are needed so that hot embossing may advance to becoming a practical technique for producing microfluidic parts. This work focuses on both the design and analysis of a hot embossing system and a brass tool to replicate an existing functional high aspect ratio micro feature onto Polymethyl methacrylate (PMMA). The aspect ratio of features ranged from 10:1 to 4,000:1. Optimal embossing parameters used a pressure of 3.5kN, hold time of 12 minutes, tool temperatures of 140°C and substrate temperature of 130°C to produce parts that filled shoulder heights and widths up to 97% and 90%, respectively. The wearing of features on the metal tool were also characterized for purposes of understanding the limits on tool use and was found that a maximum range of +/-3[mu]m in dimensional change existed. Gains in tool dimensions were then mainly attributed to the deposition of embossed materials onto the tool. The study further determined a method for creating usable resin tool copies that exhibited a replication accuracy of less than 2%, on average, for micron size features. by Khanh H. Nguyen. M.Eng. in Manufacturing 135 pages eng Massachusetts Institute of Technology M.I.T. theses are protected by copyright. They may be viewed from this source for any purpose, but reproduction or distribution in any format is prohibited without written permission. See provided URL for inquiries about permission. http://dspace.mit.edu/handle/1721.1/7582 Mechanical Engineering. Hot embossing as a method for rapid prototyping microfluidic devices Design and analysis of a hot embossing machine and the effects of toolware and accuracy of resin replication of high aspect ratio microfluidic features Thesis application/pdf false Publication unknown unknown <Publication xmlns="https://www.openaire.eu/cerif-profile/1.1/" id="7877f11a-151b-4d5c-8e80-f35df25a06e6"> <Type xmlns="https://www.openaire.eu/cerif-profile/vocab/COAR_Publication_Types">http://purl.org/coar/resource_type/c_1843</Type> <Language>eng</Language> <Title>Hot embossing as a method for rapid prototyping microfluidic devices</Title> <Subtitle>Design and analysis of a hot embossing machine and the effects of toolware and accuracy of resin replication of high aspect ratio microfluidic features</Subtitle> <PublishedIn> <Publication> </Publication> </PublishedIn> <PublicationDate>2013</PublicationDate> <Authors> <Author> <DisplayName>Nguyen, Khanh H. (Khanh Huy)</DisplayName> <Affiliation> <OrgUnit> </OrgUnit> </Affiliation> </Author> </Authors> <Editors> </Editors> <Publishers> <Publisher> <DisplayName>Massachusetts Institute of Technology</DisplayName> <OrgUnit /> </Publisher> </Publishers> <License>http://dspace.mit.edu/handle/1721.1/7582</License> <Keyword>Mechanical Engineering.</Keyword> <Abstract>Hot embossing is a growing technology proven to be capable of reproducing micro-scale features on thermoplastics and can be an effective process for rapid prototyping microfluidic devices with high aspect ratio micro features. Advantages of this manufacturing process can include tooling flexibility, fast production time, low capital cost and a vast selection of production materials. A greater understanding on the micro feature transferring capabilities and use limits of tools are needed so that hot embossing may advance to becoming a practical technique for producing microfluidic parts. This work focuses on both the design and analysis of a hot embossing system and a brass tool to replicate an existing functional high aspect ratio micro feature onto Polymethyl methacrylate (PMMA). The aspect ratio of features ranged from 10:1 to 4,000:1. Optimal embossing parameters used a pressure of 3.5kN, hold time of 12 minutes, tool temperatures of 140°C and substrate temperature of 130°C to produce parts that filled shoulder heights and widths up to 97% and 90%, respectively. The wearing of features on the metal tool were also characterized for purposes of understanding the limits on tool use and was found that a maximum range of +/-3[mu]m in dimensional change existed. Gains in tool dimensions were then mainly attributed to the deposition of embossed materials onto the tool. The study further determined a method for creating usable resin tool copies that exhibited a replication accuracy of less than 2%, on average, for micron size features.</Abstract> <Access xmlns="http://purl.org/coar/access_right" > </Access> </Publication>