Experimental investigation on laser machining of microfluidic channels in micro mold inserts

Anthuvan, Naveen (author), Vijayan, Krishnaraj (author), Valentinčič, Joško (author), Pushpam, Jenina (author)

Laser micromachining is an effective technique for fabricating intricate microfeatures with high precision and minimal thermal deformation. In this study, micropillars were fabricated on P20 steel injection mould inserts for microfluidic channel applications using a CO▫$_2$▫ laser machining system. The primary objective of this work is to optimize laser machining parameters to achieve high dimensional accuracy and stable material removal during micropillar fabrication. Laser speed, laser power, and pulse frequency were selected as key input parameters influencing the geometrical accuracy and performance of the microstructures. An optimal combination of laser speed 525 mm s▫$^{-1}$▫, power 32 W, and frequency 23 kHz was identified, resulting in highly repeatable micropillar geometry. The fabricated micropillars exhibited low dimensional variation, with length and width variations limited to 0.5% and 1.9%, respectively, while the material removal rate showed a variation of 3.0%, indicating consistent machining performance. Overall, the results demonstrate that appropriate optimization of laser parameters enables precise and repeatable fabrication of micropillars on P20 mold inserts, highlighting the suitability of laser micromachining for producing high-quality micro mold inserts for injection- molded microfluidic applications.

• Language: English
• Keywords: micropillars, laser micromachining, experimental design, optimization, mould insert
• Work type: Article
• Typology: 1.01 - Original Scientific Article
• Organization: FS - Faculty of Mechanical Engineering
• Publication status: Published
• Publication version: Author Accepted Manuscript
• Year: 2026
• Number of pages: 10 str.
• Numbering: Vol. 8, no. 3, art. 035504
• PID: 20.500.12556/RUL-179281
• UDC: 535:655.225.2
• ISSN on article: 2631-8695
• DOI: 10.1088/2631-8695/ae39b0
• COBISS.SI-ID: 267559171
• Publication date in RUL: 10.02.2026

Record is a part of a journal

• Title: Engineering research express
• ISSN: 2631-8695
• COBISS.SI-ID: 175559683

Secondary language

• Language: Slovenian

Abstract

Lasersko graviranje je učinkovita tehnologija izdelave kompleksnih mikrostruktur z visoko natančnostjo in minimalnimi toplotnimi vplivi. V raziskavi smo na orodnih iz jekla P20 na orodnih vložkih za brizganje plastike izdelali mikrostebričke v mikrofluidniih kanalih z uporabo CO▫$_2$▫ laserskega sistema. Glavni cilj je bil optimirati parametre laserske obdelave za doseganje visoke dimenzijske natančnosti in stabilnega odvzema materiala. Kot ključne vhodne parametre smo izbrali hitrost laserskega pomika, lasersko moč in frekvenco pulzov. Določena je bila optimalna kombinacija: hitrost 525 mm s▫$^{-1}$▫, moč 32 W in frekvenca 23 kHz, ki zagotovlja natančno in ponovljivo izdelano geometrijo mikrostebričkov. Izdelani mikrostebrički izkazujejo nizko dimenzijsko variabilnost (odstopanja dolžine do 0,5 % in širine do 1,9 %), variacija hitrosti odnašanja materiala pa znaša 3,0 %. Rezultati potrjujejo, da ustrezna optimizacija vhodnih parametrov omogoča natančno in ponovljivo izdelavo mikrostebričkov na vložkih iz P20, ter tako dokazujemo primernost laserskega gravoranja za izdelavo kakovostnih orodnih vložkov.

• Keywords: mikrostebrički, lasersko graviranje, načrtovanje eksperimentov, optimizacija, orodni vložek