Enhancing the robustness of nanostructures through the production of self-protective structures by injection molding of thermoplastic elastomers

Nanostructures are often proposed for anti-counterfeiting and decoration, yet their practical use is frequently limited by poor durability under mechanical stress and high production costs. To enhance the robustness of nanopatterns (specifically LIPSS), this study proposes a combined approach using sacrificial microstructures and elastomeric materials. The designed textures were fabricated through micro-injection molding (μ-IM) of thermoplastic elastomers (TPEs), a process suited for mass production. The process parameters were optimized to better understand the behavior of TPEs in μ-IM, with particular focus on replication fidelity and uniformity. Finally, the durability of the LIPSS was evaluated through abrasion tests. The results showed that melt temperature, mold temperature, and injection speed are the most influential process parameters. The integration of protective micropatterns and the use of TPE led to an increase in the durability of LIPSS of 37% and 18%, respectively.