Numerical analysis to predict the flow behavior of polymers was conducted using commercial finite element software, DEFORM-2D. An alignment structure, a hemisphere-tipped post with an annular ring, was modeled to demonstrate the flow front of the polymer during molding. The cavity filling process was evaluated by measuring the heights of the molded posts and confirmed and validated by experimental data. Estimated and measured heights showed better replication accuracy with the increase of molding temperature and embossing force. Results exposed complete cavity filling at embossing forces of 600 and 900 N at a molding temperature of 137.5°C. The FEM prediction tool can be used to select the adequate process parameters for a high fidelity replication of polymer microstructures.

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