Meaning
Specialized injection moulding of liquid crystal polymers produces micro-scale components with wall thicknesses down to zero point one millimetres and micro-gram shot weights. Precision lcp micro-moulding relies on low melt viscosity and rapid crystallization rates to fill intricate cavity features without flash. High shear rates during injection lower polymer viscosity, facilitating complete replication of sub-micron tool surface details.
Non-uniform molecular orientation along flow lines creates anisotropic mechanical strength across part cross-sections.
Tooling Requirement
Cavity venting dimensions must be kept below five micrometres to prevent severe flash while allowing air evacuation. Processing lcp micro-moulding requires ultra-precise pin clearances and electric injection units capable of high injection acceleration. Mold heating systems maintain cavity temperatures above one hundred degrees Celsius to prevent premature skin freezing in thin runners.
Core pin deflection must be calculated carefully due to high localized injection pressures near micro-gates.
Material Handling
Resins must be dried to moisture levels below zero point zero two percent to prevent hydrolytic degradation during melting. Desiccant dryers operating at one hundred and fifty degrees Celsius prepare material for processing. Regrind utilization is strictly limited because thermal history shifts polymer molecular weight distribution.
Quality Assurance
Automated optical inspection systems verify part geometry and edge sharpness immediately after ejection. Micro-part handling requires specialized vacuum end-of-arm tooling to prevent mechanical deformation during robot removal. Linear thermal expansion coefficients along the flow direction approach zero, ensuring dimensional stability in micro-connector housings.
Thermal stability enables components to withstand lead-free reflow soldering temperatures exceeding two hundred and sixty degrees Celsius.
