High-Speed Laser Surface Texturing of 3D Injection Molds for the Manufacturing of Functionalized Polymer Containers with Optimized Flow (LaMoFlo)

PROJECT COST:

199 000 $

PRIMA CONTRIBUTION:

70 000 $

PROJECT DETAILS:

A common challenge in food and waste packaging is the incomplete emptying of containers at the end of use. Food residues left inside containers can contribute to greenhouse gas emissions through decomposition, as well as to environmental impacts such as acidification and eutrophication. Improving the complete removal of food residues from packaging could therefore provide significant environmental benefits. The development of non-stick and self-draining containers represents a promising solution to address this challenge.

Researchers from McGill University, the École de technologie supérieure (ÉTS), and the Laser Institute of Mittweida University of Applied Sciences (ILM) have partnered with IPL, a world-class manufacturer of bulk and food packaging solutions, and Moulexpert, a leading manufacturer of plastic injection molds, to develop an industrial laser texturing process for molds used to manufacture polymer surfaces with structure-induced functionalities.

Specifically, this project aims to: (1) fundamentally investigate the relationship between polymer flow and micro/nano-scale surface textures through rheological studies; (2) establish a femtosecond laser machining protocol for producing textured mold surfaces used in the molding and demolding of container sidewalls, in order to create self-cleaning functionality in the resulting polymer parts; (3) evaluate lubricant infusion into textured polymer surfaces to manufacture robust, slippery, and self-healing container walls; (4) scale up laser surface processing of metal molds from the laboratory to an industrial level by identifying suitable configurations and parameters for high-throughput laser machining; and (5) texture complex industrial injection molds for the production of food and waste containers.

The results will provide direct value to the industrial partners by enabling them to expand their product lines and drive innovation in the packaging sector.

The results of this research project will have a direct impact on the lives of Quebec residents. Improved recycling of functional containers, reduced food waste, and easier compost processing will each contribute to decreasing landfill waste and reducing greenhouse gas emissions, thereby protecting the environment.

This project will also create opportunities for other industries to apply similar approaches, such as the development of structural colors and tailored wetting or adhesion properties for automotive surfaces and aircraft components.