Page 55 - Plastics News November 2025
P. 55
TECHNOLOGY NEWS
slowing production and raising the risk of dam- second systems achieve clean features without
age. Micro-asperities created by laser pulses thermal impact, though at higher cost and lower
disrupt the contact interface, diminish adhesion, throughput. Engineers balance these trade-offs
and lower frictional resistance, as demonstrated to match economic and technical goals.
by companies such as LightMotif. When com-
bined with coatings such as diamond-like carbon Uniformity across complex cavities depends on
or physical vapor deposition films, textured sur- beam stability and overlap. Small deviations dis-
faces further improve cleanliness, shorten cycle tort patterns and later appear as flaws or weak
times, and reduce unplanned downtime. zones. Designers control depth and aspect ratio
carefully: deep grooves trap resin and compli-
Durability of molds gains equal importance un- cate cleaning, while shallow features fade quick-
der repetitive service. Thermal cycling, abrasive ly or vanish under coatings.
fillers, and aggressive cleaning agents degrade
smooth surfaces rapidly. Textured geometries Material response further defines limits. Hard-
distribute stresses more evenly, eliminate sharp ened steels risk micro-cracking under steep gra-
transitions, and retain protective residues that dients, and copper alloys reflect energy unless
mitigate wear. Ultrafast pulses generate fea- wavelength and pulse control are precise. Post-
tures without heat-affected zones, preserving processing steps such as polishing or thermal
hardness and structural integrity. Tool steels, treatment often restore surface integrity.
copper alloys, and nickel alloys therefore sustain Coatings interact closely with geometry. PVD
longer service intervals when engineers calibrate or DLC films extend tool life, but sharp grooves
geometry to the intrinsic properties of each sub- create stress points that weaken adhesion. Ef-
strate. fective textures support full coverage without
sacrificing fidelity.
The influence of texturing extends beyond the
mold and into the polymer component itself. Performance verification closes the cycle. Con-
Replicated surface features define wettability, focal microscopy and interferometry measure
optical response, and tactile performance with- depth, roughness, and periodicity, while simu-
out the need for secondary treatments. Medical lation models predict flow and cooling. Regular
trays benefit from hydrophilic drainage paths, inspection after refurbishment confirms that tex-
automotive panels achieve low-glare matte fin- tures retain function and sustain quality.
ishes, and packaging lids acquire anti-smudge Emerging Directions and Trends
functionality. These properties emerge directly
from the molding process, reducing cost while
simplifying downstream recycling.
Technical Factors That Define Performance
Laser system selection dictates both precision
and productivity. Nanosecond sources run faster
and cost less but leave recast material that de-
mands extra finishing. Picosecond and femto- Injection molded TPU demonstrator sample with different soft-touch /anti-glare
micro-pillar textures. Courtesy of LightMotif.
November 2025 PLASTICS NEWS 55
