Research Unit 742


Development of Machine, Tool and Process Technologies for New Methods to Manufacture Micro Parts via Liquid Phases

Research Unit contributes to the development of new technologies for the manufacture of micro-products via the liquid phases of polymers, metals, and ceramics. It analyzes new process concepts with good prospects in the area of micro-technology.



Christian Hopmann

Director of the Institute of Plastics Processing (IKV)


+49 241 80 93838



The Research Unit sets out to master phenomena occurring specifically in the micron range also make them available for the shaping process.

Technologies under Investigation

The Research Unit investigates in particular the following technologies:

Capillary Pressure Die Casting
In capillary pressure die casting of metal micro parts, the effect of capillary rise is systematically used to fill micro moulds with melt. In consideration of micro specific properties of micro parts, concepts for a casting plant will be generated, which afterwards will be transferred into a prototype stage.

Ultra-Sonic Plastification
The plasticising of polymer resins using ultrasound has the ability to provide the small amounts of polymer melt needed for micro parts within shortest times. Research conducted in this sub-project aims at qualifying the process for different moulding materials and moreover at analysing, which conformity of the processes of ultrasonic plasticising and ultrasonic welding can be found.

Pre-Compression of Polymer Melts
Pre-compression of polymer melts in front of the cavity can provide a better filling of the mould. Especially precise reproducibility is expected from this process. In the scope of this sub-project, the technical potential of melt pre-compression will be investigated. Modelling the process allows to evaluate the melt pre-compression technique in comparison to conventional injection moulding.

Separation of Parts from Electrolyte Solutions
The separation of a material out of aqueous electrolyte solutions can be used to produce micro parts with the help of micro-structured, partially conductive polymer moulds. The objective of investigations of this process chain is to characterise the process combinations regarding its technological and economical data and to benchmark these against alternative processes.

Material Damage through the Injection Moulding Process
Another sub-project deals with research on material damage induced by the injection moulding process. These investigations will clarify whether the high surface-to-volume-ratio and the affected chemical constitution of a polymer will reduce the exploited maximum material potential.