Fabrication of Plastic Micro Tip Array using Laser Micromachining of Nanoparticles Dispersed Polymer and Micromolding

Abstract

An injection molded plastic micro tip array was fabricated. First, an inversed conical hole with a sharp tip and a high aspect ratio was fabricated by irradiating a low power output Nd:YVO₄-SHG laser beam for several milliseconds on Au nanoparticles dispersed ethylcellulose. Then, an epoxy micro tip array was fabricated by the cast method using the inversed conical hole as a mother structure. This was followed by nickel electroforming to make a nickel-mold mother. Finally, plastic injection compression molding was carried out to form the final plastic micro tip array. By optimizing several processing parameters, a polyethylene micro tip array with a height of about 100 μm and a diameter of about 50 μm was successfully realized.