nrc-london (micromachining) 2017-18

NRC-AST-London Capabilities in Micromachining by Evgueni Bordatchev NRC-AST-London [email protected]

February 2017

Evgueni Bordatchev, NRC-AST-London, 2017

High Aspect Ratio Pins

2

Ø200um

6mm

1mm square

aspect ratio = 1:30 (< 4 hrs)


High Aspect Ratio Spiral

3

1:280 aspect ratio wall: 25 um width, 7 mm height (< 9 hrs)

7 mm

25 um


Array of Vertical Tubes

4

4.9 mm

Ø1 mm Ø0.35 mm


Egg Carton 3D Structure

5

16 mm x 16 mm x 4 mm


High Aspect Ratio Honeycomb structure

6

3 mm 25µm

7mm

1:280 aspect ratio wall: 25 um width, 7 mm height (< 6 hrs)


Microfluidic die on thin metal foil

7

micro-fluidic die in brass (38 µm thick)

38um depth 15um

replica in thin PMMA sheet


Micro-Optical Structure (micro-lens)

8

a) insert b) geometry c) surface quality

30 mm x 30 mm


Die for concave micro-lens array

9

Ra = 50 ÷ 70 nm


V-groves on 3D surfaces (curved)

10

16 mm × 16 mm Brass

Sa ≤ 10 nm

pitch: 200 µm depth: 100 µm included angle: 90°

R 100 mm


V-groves on 3D surfaces (curved)

11

16 mm × 16 mm PMMA Sa ≤ 10 nm

R 100 mm



V-groves on 3D surfaces (waved)

12

16 mm × 16 mm PMMA

Sa ≤ 10 nm


R 18 mm

R 18 mm

R 18 mm


Micromilling: pyramid and thin wall

13

1 mm wall width: 0.05 mm wall depth: 2 mm aspect ratio: 1:40

Sa : 140–200 nm (pyramid side

surface) Sa: 80–100 nm

(bottom along tool path)


Bullseye Plasmonic Lens

14

top

bottom

25 mm


Linear array of V-grooves (Al) 0.25 mm step, 0.15 mm depth

15

250X

88.710

149.5um 249.35um

Cutting

controlled directional reflectivity

~90 deg ~45 deg ~65 deg


Planar Micro-optical Prismatic Elements (25 x 25 x 8 µm)

16

25µm

25µm


Direct machining of plastics (e.g. PMMA) with optical surface quality

17

direct machining of plastics with optical quality

Ra < 40 nm (max) and 17 nm (min)

40 x 40 x 40 µm pyramids (60 µm apart)

40 µm

60 µm


Flycutting machining of brass with optical surface quality

18

flycutting

Ra = 3.7 nm over 1 mm2

area


Milling of flat metallic surfaces (brass) with optical surface quality

19

micromilled plate

min Ra = 13.6 nm

Sa = 43.5 nm over 1 mm2 area


Micromilling of flat surfaces (Sa = 12 nm)

20

Sa = 12 nm 11 x 11 mm


Micromilling of a microfluidic die (brass)

21

Sa = 47.13 nm Sa = 42.04 nm

Sa = 46.71 nm Sa = 85.32 nm

10 mm

54 mm


Direct machining of plastics (e.g. PMMA) with optical surface quality (microfluidic chip)

22


Direct machining of plastics (e.g. PMMA) with optical surface quality (microfluidic chips)

23

direct machining of plastics with optical quality

Ra < 20 nm


Micromachining of Cemented Carbide (95 HRA): Surface Quality

24


Micromachining of Cemented Carbide (95 HRA): Surface quality (Sa)

25

Sa:


Light Pipe Insert (Brass)

26


Laser texturing of super-hydrophobic surfaces: Water drop test

27


Laser texturing of super-hydrophobic surfaces: Self-cleaning performance

28


Laser texturing of super-hydrophilic surfaces: Water drop test

29


Laser texturing of super-hydrophilic surfaces: Vertical super-hydrophilic time-lapse

30


Texturing of Al alloy

31

14 mm x 14 mm


Texturing of PMMA plastics

32

14 mm x 14 mm


Texturing of grey-scale images

33

10 mm x 10 mm


Texturing using retroreflective structures in plastics and in metal

34


Capabilities in Micromachining, Micro-optics and Surface Functionalization

35

Contact information: Dr. Evgueni Bordatchev NRC-AST-London Automotive and Surface Transportation 1-519-430-7107 [email protected]

nrc-london (micromachining) 2017-18

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