Chapter 6. Modeling and Process Simulation

The aim of this chapter is to enhance the in-depth understanding of the hot embossing process. Theoretical aspects will be covered as well as practical experience. In addition, the knowledge of polymer material behavior will be conveyed, which will be helpful in finding the adequate process parameter for a selected design. Furthermore, the theoretical knowledge provided will be helpful in designing microstructured molds and will demonstrate both the potentials and the limits of hot embossing processes.

In a first step, the process will be described with a simple analytical model. With this model, basic correlations can already be shown. In a second step, a detailed process simulation referring to the material behavior of thermoplastic polymers will reveal more complex correlations. The results obtained will then be used for further developments in the field of hot embossing. This chapter will present current developments in modeling and simulation and demonstrate the potentials of process simulation, but also the limits, especially as far as the molding of microstructures is concerned.