{ "id": 1847, "date": "2023-06-01T13:34:07", "date_gmt": "2023-06-01T11:34:07", "guid": { "rendered": "https:\/\/www.glossandcoating.com\/?page_id=1847" }, "modified": "2023-06-01T14:36:28", "modified_gmt": "2023-06-01T12:36:28", "slug": "liberatio", "status": "publish", "type": "page", "link": "https:\/\/www.glossandcoating.com\/en_us\/liberatio\/", "title": { "rendered": "Libera Tio – MEDICAL & PHARMACY" }, "content": { "rendered": "
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INNOVATION<\/h1>

Demolding Optimization<\/span><\/h3>
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We have developed the process \u201cNanostructuring\u201d which allows us to selectively control the tertiary structure which heavily influences the interaction between the plastic material and the tool surface, i.e., sticking, residue formation, and friction.<\/p>

It is important to know that by changing the tertiary structure with the help of Nanostructuring only the physical nature of the surface is changed, not its chemistry. Therefore, Nanostructuring is NO coating making it ideally suited for the medical industry which is typically very reluctant to use coatings to produce injection molded parts.<\/p>

While Nanostructuring has the potential to eliminate the need for coatings as an alternative for solving demolding\/sticking\/residue problems, it cannot act as a barrier to corrosive attack on tool surfaces and tool parting areas. Also, for the demolding of very challenging material such as TPU, TPE, etc., the Nanostructuring method might not be enough.<\/p>

There have been increasing problems with corrosion formation in contours and tool parting areas due to highly aggressive flame-protection used for all plastic parts related to the growing field of electromobility as well as more aggressive plastic materials used in medical injection such as COC, COP.<\/p>

There are coatings which have the potential to solve the corrosion problem (which in most cases is related to residue formation) but all have their drawbacks. While Nickel is an excellent barrier coating against corrosion it only works satisfactory above coating thicknesses of 2\/100mm - way too high for low-tolerance tools; the same holds true for PTFE-type coatings. PVD- und Chromium-type coatings are only corrosion inhibitors but have no real corrosion-protection properties. Defect-free PACVD coating such as DLC also have corrosion-protection properties, but they depict unfavorable interactions with almost all types of plastic materials. \u00a0All coatings have thicknesses between 2-3 \u00b5m.<\/p>

As an answer to this dilemma, our team has developed a coating called \u201cDuomorph\u201d with superb corrosion protection properties and a coating thickness of only 0,1 \u00b5m (!). The coating material has an FDA- and a USP Class VI (Cleanroom) certification making it ideally suited for the medical industry.<\/p><\/div><\/div>\n <\/section>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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Example<\/h2>

Application with Nanostructuring<\/span><\/h3>

The following example shows the potential of nanostructuring to reduce demolding forces associated with the injection molding process without applying a coating:<\/p>

Three cores were polished to an initial SPI-A1 finish (industry standard). One core was then treated with a fine, one with a coarse nanostructure, while one core remained in the initial high-gloss quality. The cores were then imstalled in an injection molding tool and article of transparent polycarbonate were manufactured. The transparency of these articles was not negatively affected by the nanostructuring.<\/p>

The demolding forces and the demolding path were measured during the process with the help of sensors:<\/p><\/div><\/div>\n <\/section>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Example<\/h2>

Application with Nanocoating<\/span><\/h3>

For a medical application, a customer is producing very thin mats made from TPE \u2013 an extremely difficult demolding situation.<\/p>

Due to the very strong adhesion of the TPE to the surface no production was possible \u2013 the mat was torn by the ejector pins.<\/p>

Several coatings were tested \u2013 without success.<\/p>

After applying a combination of Nanostructuring and Nanocoating to the EDM-structured surface the customer was able to produce without any problem.<\/p><\/div><\/div>\n <\/section>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Example<\/h2>

Application with Nanostructuring and Nanocoating<\/span><\/h3>

The following example shows the potential of nanostructuring in conjunction with the \"Duomorph\" nanocoating to reduce demolding forces.<\/p>

One cavity was left in its entry surface and a second cavity was treated with fine nanostructuring and the \"Duomorph\" nanocoating. The cavities were then installed in an injection molding tool and articles made of thermoplastic elastomer were produced.<\/p>

The demolding forces and the demolding path were measured during the process with the help of sensors:<\/p><\/div><\/div>\n <\/section>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Advantages<\/h2>

Nanostructuring<\/span><\/h3><\/div>\n <\/section>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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