This study focuses on the forming of dynamic microstructure of flexible polymer. The dynamic tensile control microstructure of the polymer mold, along with the gasbag, was used to exert pressure to achieve forming. This study simulated the dynamic control of the flexible mold, and proposed four mechanical models of material viscoelastic response for modeling and evaluation. MATLAB software was used to calculate the imprint prediction calculation theory construction according to the imprint result of curved surface and asymmetric imprint forming. This study designed and developed a gasbag-assisted dynamic forming system, and tested the proposed system for verification. The test results showed that the mechanical stability, curved surface, and asymmetric imprint prediction calculation of the mechanical model of the viscoelastic response of flexible mold material, as proposed in this study, can display the geometric features of the imprinted microstructure. The dynamic mold microstructure control process can accurately transfer a bifacial microstructure and construct the confidence interval for transfer printing forming.

This study proposed the belt-type microstructure array flexible mold designed hot roller embossing process technology. An extrusion molding system was integrated with belt-type hot roller embossing process technology and, deriving the asymmetric principle as the basis of prediction, designed a belt-type microstructure array hot roller embossing process system. This study first focused on the design and manufacturing of a belt-type hot roller embossing process system (roll to belt-type). It then carried out system integration and testing, along with the film extrusion system, to fabrication microstructure array production. Hot embossing was used to replicate the array of the plastic micro lens as the microstructure mold. The original master mold was fabricated with micro electromechanical technology and the PC micro lens array as the microstructure (inner layer) film using the gas-assisted hot embossing technology. A microstructure composite belt and magnetic belt were produced on the hot roller embossing by an innovated coated casting technique. The forming accuracy of the belt-type microstructure array flexible mold hot roller embossing process and the prediction precision of numerically simulated forming were discussed. The proposed process technology is expected to effectively reduce the process cycle time with the advantages of being a fast and continuous process.

This study proposed a dynamic forming mechanism development of the negative Poisson’s ratio elastomer molds—plate to plate (P2P) forming process. To dynamically stretch molds and control the microstructural shape, the proposal is committed to using the NPR structure as a regulatory mechanism. The NPR structural and dynamic parallel NPR-molds to control microstructure mold-cores were simulated and analyzed. ANSYS and MATLAB were used to simulate and predict dynamic NPR embossing replication. The hot-embossing and UV-curing dynamic NPR P2P-forming systems are designed and developed for verification. The results illustrated that the dynamic forming mechanism of the negative Poisson’s ratio elastomer molds proposed by this study can effectively control microstructure molds. This can effectively predict and calculate the geometrical characteristics of the microstructures after embossing. The multi-directional dynamic NPR microstructural replication process can accurately transfer microstructures and provide high transfer rate-replication characteristics.