Micro-structured and thus functionalized surfaces offer high potentials for new approaches in processing techniques and product design. However, for mass production purposes quite a few challenges regarding the manufacturing of these surfaces have to be overcome. For the fast and economic production of large quantities of structured polymer films the extrusion embossing process is suitable. For three-dimensional parts injection molding excels. In order to achieve a high quality of the produced micro-structured components (films/parts) variothermal laser- as well as inductor-based heating concepts are developed and implemented. Furthermore, an integrative analysis and optimization of the entire process chains is performed in close collaboration with our partners Fraunhofer Institute for Laser Technology, Surface Engineering Institute and Foundry Institute. This includes the manufacturing of suitable embossing rolls and injection molding tools, the development of coating systems and the adaption of the manufacturing process. Thus, functionalized, super hydrophobic plastic parts with static contact angles up to 165° against water are produced by replicating cone-like surface structures inspired by natural lotus leaves.

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