Special Interest Group Meeting : Structured & Freeform Surfaces

6th – 8th October 2020

Tutorial: Polymer Replication & Molding 

Tuesday 6th October 2020
Time: 09:00 – 12:30 (CEST)

The tutor is Dr Guido Tosello, PhD Associate Professor, Technical University of Denmark, DK

The tutorial describes the state-of-the-art in replication of surface texture and geometries at the micro and nano scales. The program focuses on the replication of surfaces in polymers. Three main technological areas enabled by surface replication processes will be discussed: manufacture of netshape micro/nano surfaces, tooling (i.e. master making), and surface quality control (metrology, inspection). Replication processes and methods as well as the metrology of surfaces to determine the degree of replication are presented and classified. Examples from various application areas will be presented including replication for surface texture measurements, surface roughness standards, manufacture of micro and nano structured functional surfaces, replicated surfaces for optical applications (e.g. optical gratings), and process chains based on a sequence different surface replication steps.

Tutorial Programme:

          1. Concept of polymer replication
          2. Replication processes
          3. Technologies enabled by surface replication
            a. Surface replication for surface manufacture
            b. Master making based on replication processes
            c. Surface metrology/characterization based on replication processes
          4. Determination of the degree of replication
            a. Quantification of degree of replication
            b. Metrological approaches to surface replication
            c. Simulations of polymer surface replication
          5. Application examples
            a. Surface structure/texture measurements (Surface non-destructive testing by replica method)
            b. Surface roughness standards production
            c. Functional surfaces
            d. Optical components
            e. Examples of surface replication process sequences

Tutorial Intention:

By attending the tutorial, participants will have achieved a substantial understanding of the mechanisms of polymer replication at the micro and nano scales, of the process technologies available for polymer replication, of the methods and procedures for it characterization, as well as being familiar with a number of research and industrially relevant applications.

Intended for:

This tutorial is aimed at graduate and postgraduate engineers, post-doctoral researchers, and research project managers in the field of precision manufacturing and micro/nano technologies.


Guido Tosello, PhD, is Associate Professor at the Technical University of Denmark, Department of Mechanical Engineering, Section of Manufacturing Engineering. He is senior lecturer, scientific project coordinator, industrial consultant. Guido’s principal research interests are the analysis, characterization, monitoring, control, optimization and simulation of precision moulding processes at micro and nano scales.

He has 15 years of research experience in the field of polymer replication and more than 10 years of teaching in the fields of micro/nano/precision moulding technologies.

He has published more than 80 peer-reviewed articles in international scientific journals and more than 190 peer-reviewed papers at international conferences and is the editor of the book “Micro Injection Molding” published by Carl Hanser Verlag in 2018.

Guido Tosello is the recipient of the “Technical University of Denmark Best PhD Research Work 2008 Prize” for his PhD thesis “Precision Moulding of Polymer Micro Components”.

Guido Tosello is currently the Project Coordinator of the H2020 MSCA ITN DIGIMAN4.0 “DIGItal MANufacturing Technologies for Zero-defect Industry 4.0 Production” (2019-2022) and has been the project coordinator of the H2020 MSCA ITN MICROMAN “Process Fingerprint for Zero-defect Net-shape MICROMANufacturing” from 2015 to 2019.

Guido holds an Executive MBA degree from the Technical University of Denmark Executive School of Business.

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