title: Study of double-side ultrasonic embossing for fabrication of microstructures on thermoplastic polymer substrates.
abstract: Double-side replication of polymer substrates is beneficial to the design and the fabrication of 3-demensional devices. The ultrasonic embossing method is a promising, high efficiency and low cost replication method for thermoplastic substrates. It is convenient to apply silicon molds in ultrasonic embossing, because microstructures can be easily fabricated on silicon wafers with etching techniques. To reduce the risk of damaging to silicon molds and to improve the replication uniformity on both sides of the polymer substrates, thermal assisted ultrasonic embossing method was proposed and tested. The processing parameters for the replication of polymethyl methacrylate (PMMA), including ultrasonic amplitude, ultrasonic force, ultrasonic time, and thermal assisted temperature were studied using orthogonal array experiments. The influences of the substrate thickness, pattern style and density were also investigated. The experiment results show that the principal parameters for the upper and lower surface replication are ultrasonic amplitude and thermal assisted temperature, respectively. As to the replication uniformity on both sides, the ultrasonic force has the maximal influence. Using the optimized parameters, the replication rate reached 97.5% on both sides of the PMMA substrate, and the cycle time was less than 50 s.
authors: Key Laboratory for Micro/Nano Technology and System of Liaoning Province, Dalian University of Technology, Dalian, China. luoy@dlut.edu.cn
authors: Yi
authors: Y
authors: Luo
authors: Xu
authors: X
authors: Yan
authors: Na
authors: N
authors: Qi
authors: Xiaodong
authors: X
authors: Wang
authors: Liangjiang
authors: L
authors: Wang
mesh_terms: D000704:Analysis of Variance; D004867:Equipment Design; D006358:Hot Temperature; D008420:Manufactured Materials; D008855:Microscopy, Electron, Scanning; D019904:Polymethyl Methacrylate / Q000737:chemistry*; D013016:Sound; D013314:Stress, Mechanical; D013499:Surface Properties
chemical_list: D019904:Polymethyl Methacrylate
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