Manufacturing routes for replicating micro and nano surface structures with bio-mimetic applications

In order to broaden the application domain of microsystems-based products, a number of processing chains that are complementary to those used for batch-manufacturing of micro electro mechanical systems (MEMS) have been recently proposed by the research community. Such alternative process chains combine micro and nano structuring technologies for master making with replication techniques for high throughput such as injection moulding (IM). In this research, two new process chains were investigated for replicating structured surfaces that are inspired by nature. In particular, a study was conducted to replicate structures incorporating functional features found on the eye of a household fly and on a shark skin. Such features were initially designed by applying a bio-mimetic modelling approach to generate the 3D models necessary to achieve the targeted surface functionality and thus to investigate the feasibility of “embedding” them in existing and new emerging products. The proposed two process chains employ micro-second (ms) and pico-second (ps) laser ablation and focused ion beam (FIB) milling to perform micro and nano structuring, respectively. The feasibility of applying them for producing masters for replicating bio-inspired surface structures was investigated by performing micro injection moulding trials. The results showed that such micro and nano structured surfaces can be replicated successfully, and the two process chains can be considered as promising manufacturing routes for serial production of parts incorporating bio-inspired surface structures.