Periodic Reporting for period 2 - Himalaia (High-Impact Injection Moulding Platform for mass-production of 3D and/or large micro-structured surfaces with Antimicrobial, Self-cleaning, Anti-scratch, Anti-squeak and Aesthetic functionalities)
Berichtszeitraum: 2019-03-15 bis 2021-03-14
Surface properties need to be controlled and modified to satisfy demanding engineering requirements in many applications: packaging, automotive, health, aerospace, energy, etc. In recent years, the manufacturing of functional polymer surfaces (antimicrobial, anti-scratch, self-cleaning, etc.) has been tackled through the injection moulding (IM) replication of micron and sub-micron structures, but only for small areas of 2D to 2.5D parts. However, the technologies’ limitation to flat, simple and small surfaces is a bottleneck to broad application and major industrial breakthrough.
HIMALAIA’s concept for a mass production line synergistically combines the latest advances in nano- and micro-scale surface modification methods, advanced tool-making technologies and micro-replication IM. The resulting platform allows the highly efficient production of large and/or 3D thermoplastic parts with functional micron and sub-micron topographies, providing antimicrobial, anti-scratch, self-cleaning, anti-squeak and optical properties. The platform is broadly applicable to many sectors, including health, energy, telecommunications, etc. By avoiding functionalization coatings, HIMALAIA technologies contribute to the environmental impact reduction: removal of ecotoxic compounds, replacement of energy-consuming post-processes, and facilitation of the recycling.
The five overall objectives are summarised below:
1. To develop technologies for advanced moulds able to replicate with high accuracy and durability complex 3D shapes with micron and sub-micron surface topographies for advanced properties: self-cleaning, antimicrobial, anti-scratch, anti-squeak and aesthetics.
2. To develop an in-process characterization tool to elucidate the dependencies between surface topographies of polymer parts and their functional responses.
3. To develop optimized IM techniques for accurate and reliable replication of micron and sub-micron topographies on 3D / large parts.
4. To integrate the previous building blocks into a flexible, factory-relevant TRL6 design and manufacturing platform.
5. To demonstrate and transfer broadly the HIMALAIA manufacturing platform.
At the end of the project, the HIMALAIA consortium has fully achieved the targeted objectives. The HIMALAIA platform combining the technology building blocks was set-up and validated through 3 representative use-cases. Their characterization validated the efficiency of the surface functionalization by the replication of micron and sub-micron surface topographies, in an industrially-relevant configuration.
HIMALAIA’s concept for a mass production line synergistically combines the latest advances in nano- and micro-scale surface modification methods, advanced tool-making technologies and micro-replication IM. The resulting platform allows the highly efficient production of large and/or 3D thermoplastic parts with functional micron and sub-micron topographies, providing antimicrobial, anti-scratch, self-cleaning, anti-squeak and optical properties. The platform is broadly applicable to many sectors, including health, energy, telecommunications, etc. By avoiding functionalization coatings, HIMALAIA technologies contribute to the environmental impact reduction: removal of ecotoxic compounds, replacement of energy-consuming post-processes, and facilitation of the recycling.
The five overall objectives are summarised below:
1. To develop technologies for advanced moulds able to replicate with high accuracy and durability complex 3D shapes with micron and sub-micron surface topographies for advanced properties: self-cleaning, antimicrobial, anti-scratch, anti-squeak and aesthetics.
2. To develop an in-process characterization tool to elucidate the dependencies between surface topographies of polymer parts and their functional responses.
3. To develop optimized IM techniques for accurate and reliable replication of micron and sub-micron topographies on 3D / large parts.
4. To integrate the previous building blocks into a flexible, factory-relevant TRL6 design and manufacturing platform.
5. To demonstrate and transfer broadly the HIMALAIA manufacturing platform.
At the end of the project, the HIMALAIA consortium has fully achieved the targeted objectives. The HIMALAIA platform combining the technology building blocks was set-up and validated through 3 representative use-cases. Their characterization validated the efficiency of the surface functionalization by the replication of micron and sub-micron surface topographies, in an industrially-relevant configuration.
In WP1, main specifications were defined: end users’ demonstrators, injection mould platform, and functional characterization methods. In addition, feasibility trials of surface textures were performed to define their applicability for the target functional responses.
In WP2, several surface texturing and surface engineering technologies were successfully developed: active plasma hardening, nitriding and carburising to increase highly the hardness of end-users’ materials, particles self-assembly on 2D and 3D shape for large area texturing. A new feature in GFMS software was also developed for 3D texturing of directional textures.
In WP3, LIPSS patterns and tooling surfaces replication using IM processes was assessed through a range of multifunctional tooling to study the process variants influence on the replication quality. Detailed material characterisation was performed and a number of component ‘Building Blocks’ were created to improve replication quality (process monitoring system, simulation, etc.) and define optimised process environments.
In WP4, characterization and test methods were developed and validated for the targeted properties: contact angles, anti-microbial, anti-scratch, anti-squeak, self-cleaning. The in-line surface metrology tool and method was developed. The elaborated nano-object release analysis method validated the safety of HIMALAIA polymer parts. Finally, a model-based surface characterization method for correlations of functional response with process, characterization and simulation data was developed and assessed.
In WP5, the replication platform was completed with all the building blocks: a 70 tons IM machine, a 6 axis robot, a vehicle test mould, a Heat & Cool equipment, a Data Acquisition System, a Cobot, the Alicona in-line measurement tool, and a CO2 cleaning system. In parallel, textured inserts were tested via many production trials including runs in full automatic conditions. The Zero-Defect strategy was implemented and a validation procedure was produced.
In WP6, considerable End of Life potential with HIMALAIA was demonstrated: energy savings and less carbon footprint for Albea and EO demonstrators. Total Cost and Benefits of Ownership were evaluated and constitute a valuable decision-making tool for future users of the HIMALAIA technology. CRF produced and successfully assessed an automotive interior trim with new functional textures. EO designed, manufactured and tested small size brackets with antibacterial properties. Albéa produced a demonstrator with visible characteristics to show to marketing teams and customers.
In WP7, several communication and dissemination activities were conducted using various channels in order to reach a large audience: 1 website created, 24 scientific publications, 8 talks in conferences, … Finally, a dedicated workshop was organized to present the HIMALAIA platform to future customers.
In WP8, new knowledge and IP was monitored and 1 patent was filed. The “7 core innovations” of HIMALAIA were identified, and partners’ strategy defined: value creation and financial projection towards 2030, based on the technical outcomes of the HIMALAIA project. The exploitation plan was elaborated in 2 Exploitation Strategy Seminars, resulting in the definition of the platform’s business model with the identified list of services. The transfer to industry was investigated at companies-level and daughter platforms-level, with the production of guidelines.
In WP2, several surface texturing and surface engineering technologies were successfully developed: active plasma hardening, nitriding and carburising to increase highly the hardness of end-users’ materials, particles self-assembly on 2D and 3D shape for large area texturing. A new feature in GFMS software was also developed for 3D texturing of directional textures.
In WP3, LIPSS patterns and tooling surfaces replication using IM processes was assessed through a range of multifunctional tooling to study the process variants influence on the replication quality. Detailed material characterisation was performed and a number of component ‘Building Blocks’ were created to improve replication quality (process monitoring system, simulation, etc.) and define optimised process environments.
In WP4, characterization and test methods were developed and validated for the targeted properties: contact angles, anti-microbial, anti-scratch, anti-squeak, self-cleaning. The in-line surface metrology tool and method was developed. The elaborated nano-object release analysis method validated the safety of HIMALAIA polymer parts. Finally, a model-based surface characterization method for correlations of functional response with process, characterization and simulation data was developed and assessed.
In WP5, the replication platform was completed with all the building blocks: a 70 tons IM machine, a 6 axis robot, a vehicle test mould, a Heat & Cool equipment, a Data Acquisition System, a Cobot, the Alicona in-line measurement tool, and a CO2 cleaning system. In parallel, textured inserts were tested via many production trials including runs in full automatic conditions. The Zero-Defect strategy was implemented and a validation procedure was produced.
In WP6, considerable End of Life potential with HIMALAIA was demonstrated: energy savings and less carbon footprint for Albea and EO demonstrators. Total Cost and Benefits of Ownership were evaluated and constitute a valuable decision-making tool for future users of the HIMALAIA technology. CRF produced and successfully assessed an automotive interior trim with new functional textures. EO designed, manufactured and tested small size brackets with antibacterial properties. Albéa produced a demonstrator with visible characteristics to show to marketing teams and customers.
In WP7, several communication and dissemination activities were conducted using various channels in order to reach a large audience: 1 website created, 24 scientific publications, 8 talks in conferences, … Finally, a dedicated workshop was organized to present the HIMALAIA platform to future customers.
In WP8, new knowledge and IP was monitored and 1 patent was filed. The “7 core innovations” of HIMALAIA were identified, and partners’ strategy defined: value creation and financial projection towards 2030, based on the technical outcomes of the HIMALAIA project. The exploitation plan was elaborated in 2 Exploitation Strategy Seminars, resulting in the definition of the platform’s business model with the identified list of services. The transfer to industry was investigated at companies-level and daughter platforms-level, with the production of guidelines.
The HIMALAIA project proposes seven main scientific and technical innovations in terms of functional surfaces and dedicated characterisation techniques:
• Functional 3D polymer surfaces on large 3D parts
• Highly accurate and repeatable laser-based texturing technologies for 3D mould cavities
• Innovative stainless-steel surface engineering solutions to improve the robustness of micron/sub-micron structured 3D mould cavities
• Micro-/ nanostructuration of 3D mould cavities based on particle self-assembly processes
• Highly efficient IM-based replication process for 3D micron / sub-micron structured plastic parts
• Model for the design of functional micro-structured surfaces
• In-line monitoring and inspection tool for zero-defect strategy implementation
The research team dedicated to HIMALAIA have a long and impressive record of accomplishments in the exploitation of research results, through the commercialisation of new products and services, IP generation and technology transfer. Partners recognise HIMALAIA as a great opportunity to generate highly exploitable results.
• Functional 3D polymer surfaces on large 3D parts
• Highly accurate and repeatable laser-based texturing technologies for 3D mould cavities
• Innovative stainless-steel surface engineering solutions to improve the robustness of micron/sub-micron structured 3D mould cavities
• Micro-/ nanostructuration of 3D mould cavities based on particle self-assembly processes
• Highly efficient IM-based replication process for 3D micron / sub-micron structured plastic parts
• Model for the design of functional micro-structured surfaces
• In-line monitoring and inspection tool for zero-defect strategy implementation
The research team dedicated to HIMALAIA have a long and impressive record of accomplishments in the exploitation of research results, through the commercialisation of new products and services, IP generation and technology transfer. Partners recognise HIMALAIA as a great opportunity to generate highly exploitable results.