Rapid fabrication of microcomponents – UV-laser assisted prototyping, laser micro-machining of mold inserts and replication via photomolding

The rapid fabrication of microcomponents made from polymers or composites will be presented. The whole fabrication process is divided into three main steps: first, direct patterning of polymers with excimer laser radiation enables the fabrication of first prototypes. Second, laser assisted micromachining using Nd:YAG or KrF-Excimer laser radiation allows a rapid manufacturing of microstructured mold inserts made of steel or polymer. Third, the application of UV-light-induced reaction injection molding (UV-RIM, photomolding) process using reactive monomer/polymer resins gives the access to the replication of the previously fabricated mold insert. For mold insert fabrication, the development of different process strategies is in progress in order to meet the best fit for three dimensional shapes (e.g., steep walls or slowly inclined walls). The development of mold inserts made of polymers is performed via UV laser ablation. This is a new promising method for the rapid manufacturing of microcomponents.