Method of forming a mold and molding a micro-device
First Claim
1. A method of forming a mold for a micro-device including an array of microfeatures, comprising:
- providing a master having a surface contour which includes skin penetration features;
wherein said surface contour of said master is formed by micro-machining;
covering the surface contour with a layer of material;
removing the master from the layer of material to form a negative image of the master in the layer of material wherein the negative image is fillable by a flowable process;
filling the negative image fluidically with a flowable material to form a device having substantially the same features as the master;
solidifying said flowable material; and
separating said device from said negative image.
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Accused Products
Abstract
A method of forming a device including a plurality of micron or sub-micron sized features is provided. A master having a surface contour defining a plurality of features is provided. The surface contour of the master is coated with at least one layer of material to form a shell. The master is removed from the shell to form a negative image of the surface contour in the shell. The negative image in the shell is filled with material, for example, polycarbonate, polyacrylic, or polystyrene, to form a device having features substantially the same as the master. The negative image may be filled using injection molding, compression molding, embossing or any other compatible technique.
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Citations
33 Claims
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1. A method of forming a mold for a micro-device including an array of microfeatures, comprising:
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providing a master having a surface contour which includes skin penetration features;
wherein said surface contour of said master is formed by micro-machining;
covering the surface contour with a layer of material;
removing the master from the layer of material to form a negative image of the master in the layer of material wherein the negative image is fillable by a flowable process;
filling the negative image fluidically with a flowable material to form a device having substantially the same features as the master;
solidifying said flowable material; and
separating said device from said negative image. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A method of forming a device including a plurality of micron or sub-micron sized features, the method comprising:
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providing a master having a surface contour defining skin penetration features;
coating the surface contour of the master with at least one layer of sinterable material;
sintering said sinterable material;
removing the master from the layer of material to form a negative image of the surface contour in the layer of material;
forming a mold insert from the negative image;
filling the negative image fluidically with a flowable material to form a device having substantially the same features as the master; and
separating said device formed from said flowable material from the negative image. - View Dependent Claims (16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33)
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Specification