2011 Award Winners
Award-winning project: Highly dynamic variothermal technology for the production of microfluidic components
Project partners: Sony DADC Austria AG | Watlow Plasmatech GmbH | Steinbeis Transfer Center Plastics Center/Bretzfeld
The use of microfluidic components in the field of medical technology is increasing dramatically. As these components are mainly single-use products – for example, due to the risk of contamination – there is an enormous need for a cost-effective mass production process for them. Much like the manufacture of optical data storage media such as CDs or DVDs – which are also microstructured plastic components – injection moulding of thermoplastic moulding compounds is a suitable method here. However, the components to be manufactured are subject to extremely high quality requirements regarding microstructure replication and their internal morphology. The injection moulding techniques used to date are not sufficient to meet these requirements.
The Steinbeis Transfer Centre ‘Plastics Centre’ in Bretzfeld has been working for over ten years on the replication of functional surface structures in the micro- and nanometre range on the surfaces of macroscopic plastic components. It has been recognised that, in particular, the temperature of the mould wall plays a decisive role in the production of high-quality, microstructured plastic components. To this end, research was conducted into various temperature control systems designed to precisely regulate the temperature of the mould wall in injection moulding tools. These systems enable the highly dynamic variothermal (HDV) injection moulding of thermoplastic moulding compounds, which is essential for the replication of microstructures. In collaboration with Watlow Plasmatech GmbH in Kuchl (Austria), a manufacturer of thermally sprayed electric film heating elements, HDV temperature control modules and the associated control and regulation technology were developed.
More than 20 years ago, the Japanese Sony Group decided to establish Sony DADC Austria AG in Anif near Salzburg for the production of CDs. Today, the company is Europe’s largest disc manufacturer. With more than two decades’ experience in the mass production of microstructured plastic components, Sony DADC now also offers this service to customers outside the entertainment industry.
As part of a joint technology transfer project between the partners mentioned above, the HDV technology developed by Watlow and the Steinbeis Transfer Centre ‘Plastics Centre’ was introduced at the Sony DADC site in Anif for the manufacture of microstructured medical technology components.