A framework of a continuous injection direct rolling process for precision manufacturing plastic plates with patterned microstructures

Lingbao Kong, Jibin Li, Chi Fai Cheung, Yan Lou, Changsheng Wang, Huaiwei Peng, Chunghong Mak, Da Li

Research output: Chapter in book / Conference proceedingConference article published in proceeding or bookAcademic researchpeer-review


This paper presents an integrated roller embossing process named Continuous Injection Direct Rolling (CIDR) process. The CIDR process is similar to Continue Casting Direct Rolling (CCDR) process for metal material. The process consists of Plastic Injection Module, Injection Nozzle, Precision Rolling Module, and Automatic Coiling Module. In the proposed CIDR process, the plastic plate with microstructured pattern is produced by the integrated injection and rolling process, which is different from the current rolling or plastic injection process. Some key technologies including injection nozzle design, roller design, roller coupling, and ultra-precision machining of rollers, are presented. An on-machine measurement method is also proposed and presented to avoid the incontinence and errors caused by disassembling the roller workpiece for off-line measurement. The results of the pilot study are also discussed. The research work provides an enabling solution for precision manufacturing plastic plate and film with microstructured patterns.
Original languageEnglish
Title of host publicationPrecision Engineering and Nanotechnology V
PublisherTrans Tech Publications Ltd
Number of pages7
ISBN (Print)9783038352112
Publication statusPublished - 1 Jan 2015
Event5th International Conference on Asian Society for Precision Engineering and Nanotechnology, ASPEN 2013 - Taipei, Taiwan
Duration: 12 Nov 201315 Nov 2013

Publication series

NameKey Engineering Materials
ISSN (Print)1013-9826


Conference5th International Conference on Asian Society for Precision Engineering and Nanotechnology, ASPEN 2013


  • Continuous injection direct rolling
  • On-machine measurement
  • Optical plastic plate
  • Patterned microstructure
  • Precision injection
  • Precision rolling
  • Ultra-precision machining

ASJC Scopus subject areas

  • Materials Science(all)
  • Mechanics of Materials
  • Mechanical Engineering

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