Abstract Scope |
In this work, we explore the hybrid integration of injection molding with in-situ direct-write additive manufacturing. Specifically, we characterize a novel fabrication technique in which one prints structures directly onto an injection mold surface. During injection molding process, the polymer melt flows over the printed trace, and that trace is "transferred" from the mold into the polymer part. The resulting composite structure maintains all trace properties including: trace size, shape, and continuity. This transfer process enables volumetric integration of both structural electronics and/or mechanical reinforcement, enables wider printed curing/sintering temperature ranges, and improves surface finish compared to post-process printing. This work describes the relative surface energies of custom mold coatings which enable the printed traces to be "transferred" intact into the bulk polymer part. We also explore both mechanical and electrical properties of the final part including: adhesion, mechanical degradation, surface finishes, and integrated electrical functionality. |