Microstructuring: The Future of Functionalization

A new way to improve material properties

Thanks to microstructures, we can impart functionality to a material that it did not originally possess. For example, we can make a material self-cleaning or antibacterial without adding any coating or chemical agent.

At ATRIA, we design and manufacture microstructures that enhance the properties of any material. We are committed to the development of this technology, as we believe it is the future of industrial functionalization.

Alfredo Esteban

Expert in Microstructuring at ATRIA

Microstructuring techniques in materials

The industrial microstructuring process of materials allows us to modify material properties at a microscopic scale. This can be achieved through various techniques, which we tailor to the needs of each application.

With this technique, we laser mark the interior of the mold, creating a unique roughness on the injected pieces. This enables us to impart different properties such as hydrophobicity, oleophobicity, bactericidal effects, or aesthetic enhancements.

This method is particularly suitable for plastic components, and at ATRIA, we have extensive experience in Injection Molding Machine (IMM) projects.

We apply microstructures to materials in the form of coils through Roll-to-Roll (R2R) microstructuring. This technique involves passing the material through microstructured rollers. Pressure and, occasionally, temperature, transfer the microstructure to the material.

The process requires initial optimization, but once implemented, it is straightforward and does not require additional consumables. At ATRIA, we have experience in R2R microstructuring and have successfully executed various projects.

We create microscopic structures on a surface using laser microstructuring. It is similar to using a chisel or milling machine, but instead of physical tools, we use a beam of light. The light beam is so small that it can only be seen with a microscope.

We employ this technique on a diverse range of materials, making it a popular choice for mold and roller preparation used in 3D printing and roll coating.

Our goal is to identify the most suitable technology for the needs detected in the analysis phase of each project.

What is functional microstructuring?

Functional microstructuring is the solution to enhance the properties of your material. Through two phases, we can create patterns or structures at the micro level on the surface of your material to make it stronger, more resistant, or absorbent.

We leverage our expertise in laser technology and structure transfer methods such as IMM or R2R, enabling the process to be conducted on an industrial scale.

1

In the first phase, we dive into designing the perfect microstructure for your material. We explore various options based on our expertise and your requirements. Subsequently, we microstructure test molds and manufacture samples to assess the performance of each design. This process allows us to select the ideal microstructure.

2

Once we have the microstructure design, we move on to the production phase. For injected or extruded pieces, the microstructure is applied to the mold walls. In the case of textiles, films, or metal sheets, the microstructure is transferred to the material through rollers that we also microstructure.

3

After confirming that the technology meets our client’s requirements, we assist them in the integration process within their manufacturing workflow.

Our laboratory equipment

In our laboratory, we have an extensive range of equipment to perform all kinds of microstructuring analyses.

To create microstructured molds, we utilize a modified plastic injection molding machine. These molds have a microscopic-level structure that modifies the properties of the injected pieces to achieve the desired outcome.

Thanks to microstructured rollers, we transfer the structure onto the plastic film or metal coil that passes through them.

With a variable spot diameter, this equipment is the most versatile in our range. With it, we can create microscopic structures of any size, ranging from 10 to 100 microns.

Thanks to its ultra-short pulses, this technology prevents heat from spreading, ensuring results of the highest quality.

This technique is ideal for modifying material properties through a heat treatment.

With the optical microscope, we can analyze in detail the microstructure of a material and assess how it has been transferred to the final product.

Applications of microstructure

By altering the surface structure of a material, we can achieve highly useful applications. The possibilities of functional microstructuring are expanding, and at ATRIA, we are always at the forefront to bring this technology closer to your projects in the industry.

We have developed a catalog of non-stick microstructures for all types of plastics. Each microstructure is designed for a specific type of plastic (PP, PC, PA, etc.). These microstructures are highly useful in sectors such as appliances, automotive, and retail.

With roll-to-roll technology, we make textiles hydrophobic without the need for any coating or lacquer. This process can be applied to different textile materials by adjusting pressure and temperature.

One of the most promising applications of microstructuring is the creation of antimicrobial surfaces. In our laboratory, we have developed an injection molding technique with this property, which we can use to enhance the performance of household appliances.

With the surface microstructuring of metal sheets, we achieve this self-cleaning functionality on an industrial scale. This application is crucial in the automotive industry, where it is used to reduce maintenance and enhance efficiency.

Working with smaller microstructures, we can repel oily liquids. In this way, we have developed solutions that leverage this effect to create materials more resistant to grease, using both IMM and Roll-to-Roll processes.

Our projects

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Materials and Testing

We designed an oleophobic microstructuration laser process for injection mold, to later transfer it to a plastic part.

Materials and Testing

Materials and Testing

Other technologies

We select, apply, and test smart materials that respond to external stimuli in a controlled manner.

We develop and apply layers on a material to enhance its surface properties or provide it with new functionalities.

We create tiny holes in a material, thereby modifying its properties, allowing us to control the flow of elements passing through it.

We investigate the causes of failures in an industrial process or commercial product and propose customized solutions to resolve them.

We analyze the properties and behavior of your materials with specialized equipment to help you choose the right material for your project.

We select and conduct tests that best suit your needs and those of your product, utilizing our wide range of equipment to ensure its quality and safety.

We can change the characteristics of a material in a controlled way, improving its performance and broadening its areas of application.

Contact

Your success is our goal. We want to be your partner in the development of your projects, leveraging the power of innovation, flexibility, and the trust we provide. Together, we make a difference through new technologies.

Contact us and let’s build the future together!

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