Methods for Manufacturing Three-Dimensional Devices and Devices Created Thereby

• US 20080246180A1
• Filed: 06/18/2008
• Published: 10/09/2008
• Est. Priority Date: 06/05/2001
• Status: Active Grant

• Current Assignee: Raytheon Technologies Corporation d/b/a RTX (Rtx Corporation)
• Original Assignee: Mikro Systems, Inc.
• Inventors: Fraser, Iain, Appleby, Michael P., Atkinson, James E.
• Granted Patent: US 9,208,916 B2
• Time in Patent Office: Days
• US Class Current: 264/220
• CPC Class Codes: A61B 6/4258 for detecting non x-ray radiation, e.g. gamma radiation A61B6/037 takes precedence
• CPC Class Codes: A61B 6/502 for diagnosis of breast, i.e. mammography
• CPC Class Codes: B22D 19/00 Casting in, on, or around objects which form part of the product B22D23/04 takes precedence; alumino-thermic welding B23K23/00; coating by casting molten material on the substrate C23C6/00
• CPC Class Codes: B22D 29/00 Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots B22D13/10, B22D11/124, B22D17/00 take precedence
• CPC Class Codes: B23P 15/246 Laminated dies
• CPC Class Codes: B28B 7/20 Moulds for making shaped articles with undercut recesses, e.g. dovetails
• CPC Class Codes: B28B 7/24 Unitary mould structures with a plurality of moulding spaces , e.g. moulds divided into multiple moulding spaces by integratable partitions, mould part structures providing a number of moulding spaces in mutual co-operation assemblies of individually complete moulds B28B7/26
• CPC Class Codes: B29C 33/0088 Multi-face stack moulds
• CPC Class Codes: B29C 33/12 with incorporated means for positioning inserts, e.g. labels positioning reinforcements B29C70/541
• CPC Class Codes: B29C 33/302 Assembling a large number of mould elements to constitute one cavity
• CPC Class Codes: B29C 33/3842 Manufacturing moulds, e.g. shaping the mould surface by machining
• CPC Class Codes: B29C 33/42 characterised by the shape of the moulding surface, e.g. ribs or grooves
• CPC Class Codes: B29C 33/424 Moulding surfaces provided with means for marking or patterning for injection moulding B29C45/372
• CPC Class Codes: B29C 33/44 with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
• CPC Class Codes: B29C 39/021 by casting in several steps
• CPC Class Codes: B29C 39/34 for undercut articles
• CPC Class Codes: B29C 39/36 Removing moulded articles
• CPC Class Codes: B29C 48/12 Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
• CPC Class Codes: B29C 69/001 a shaping technique combined with cutting, e.g. in parts or slices combined with rearranging and joining the cut parts for reinforced material B29C70/545; B29C49/4278, B29C51/268 take precedence
• CPC Class Codes: B29K 2083/00 Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as moulding material
• CPC Class Codes: B29L 2031/756 : Microarticles, nanoarticles
• CPC Class Codes: G01T 1/20 : with scintillation detectors
• CPC Class Codes: G01T 7/00 : Details of radiation-measuring instruments
• CPC Class Codes: G03F 7/0017 : for the production of embossing, cutting or similar devices; for the production of casting means
• CPC Class Codes: G21K 1/02 : using diaphragms, collimators
• CPC Class Codes: Y10T 428/31 : Surface property or characteristic of web, sheet or block

Abstract

In certain exemplary embodiments of the present invention, three-dimensional micro-mechanical devices and/or micro-structures can be made using a production casting process. As part of this process, an intermediate mold can be made from or derived from a precision stack lamination and used to fabricate the devices and/or structures. Further, the micro-devices and/or micro-structures can be fabricated on planar or nonplanar surfaces through use of a series of production casting processes and intermediate molds. The use of precision stack lamination can allow the fabrication of high aspect ratio structures. Moreover, via certain molding and/or casting materials, molds having cavities with protruding undercuts also can be fabricated. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. This abstract is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b).

Claims

1. A device comprising:

a first consumable ceramic non-planar mold defining a plurality of spaces, each space from said plurality of spaces at least partially bounded by a cast wall comprising a plurality of wall surfaces, a wall surface from said plurality of wall surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a parent mold surface defined by a plurality of layers of a metallic foil stack lamination parent mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, said plurality of wall surfaces for each cast wall defining a periphery of a layer-less volume.

2. The device of claim 1, further comprising:

a channel extending through a predetermined set of cast walls of said first consumable ceramic non-planar mold.

3. The device of claim 1, further comprising:

a plurality of channels extending within said first consumable ceramic non-planar mold.

4. The device of claim 1, further comprising:

an interconnected plurality of channels extending within said first consumable ceramic non-planar mold.

5. The device of claim 1, further comprising:

a plurality of protrusions defined by said first consumable ceramic non-planar mold.

6. The device of claim 1, further comprising:

a sub-cavity defined by said first consumable ceramic non-planar mold.

7. The device of claim 1, further comprising:

a second consumable ceramic mold attached to said first consumable ceramic non-planar mold.

8. The device of claim 1, further comprising:

a second consumable ceramic non-planar mold attached to said first consumable ceramic non-planar mold, said second consumable ceramic non-planar mold comprised of at least one different material than said first consumable ceramic non-planar mold.

9. The device of claim 1, wherein:

said first consumable ceramic non-planar mold is comprised of silica, alumina, and/or zirconium oxide.

10. The device of claim 1, wherein:

at least one wall surface from said plurality of wall surfaces is non-planar.

11. The device of claim 1, wherein:

at least one wall surface from said plurality of wall surfaces is anisotropic.

12. The device of claim 1, wherein:

at least one wall surface from said plurality of wall surfaces is isotropic.

13. The device of claim 1, wherein:

at least one wall surface from said plurality of wall surfaces has a predetermined surface finish.

14. The device of claim 1, wherein:

at least one space from said plurality of spaces has a substantially triangular cross-section.

15. The device of claim 1, wherein:

at least one space from said plurality of spaces has a substantially rectangular cross-section.

16. The device of claim 1, wherein:

at least one space from said plurality of spaces has a substantially square cross-section.

17. The device of claim 1, wherein:

at least one space from said plurality of spaces has a substantially hexagonal cross-section.

18. The device of claim 1, wherein:

at least one space from said plurality of spaces has a substantially circular cross-section.

19. A device comprising:

a first consumable ceramic non-planar mold insert comprising a plurality of interconnected channel molds, each channel mold from said plurality of channel molds at least partially defined by a corresponding cast wall comprising a plurality of wall surfaces, a wall surface from said plurality of wall surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a parent mold surface defined by a plurality of layers of a metallic foil stack lamination parent mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, said plurality of wall surfaces for each cast wall defining a periphery of a layer-less volume.

20. The device of claim 19, wherein:

said first consumable ceramic non-planar mold insert comprises silica.

21. The device of claim 19, wherein:

said first consumable ceramic non-planar mold insert comprises alumina.

22. The device of claim 19, wherein:

said first consumable ceramic non-planar mold insert comprises zirconium oxide.

23. The device of claim 19, wherein:

at least one wall surface from said plurality of wall surfaces is non-planar.

24. The device of claim 19, wherein:

at least one wall surface from said plurality of wall surfaces is anisotropic.

25. The device of claim 19, wherein:

at least one wall surface from said plurality of wall surfaces is isotropic.

26. The device of claim 19, wherein:

at least one wall surface from said plurality of wall surfaces has a predetermined surface finish.

27. A device comprising:

a first consumable ceramic non-planar mold insert defined by at least one cast wall comprising a plurality of wall surfaces, a wall surface from said plurality of wall surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a parent mold surface defined by a plurality of layers of a metallic foil stack lamination parent mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, said plurality of wall surfaces defining a periphery of a layer-less volume.

28. The device of claim 27, further comprising:

a second consumable ceramic mold insert attached to said first consumable ceramic non-planar mold insert.

29. The device of claim 27, further comprising:

a second consumable ceramic non-planar mold insert attached to said first consumable ceramic non-planar mold insert, said second consumable ceramic non-planar mold insert comprised of at least one different material than said first consumable ceramic non-planar mold insert.

30. The device of claim 27, wherein:

said first consumable ceramic non-planar mold insert is comprised of silica, alumina, and/or zirconium oxide.

31. The device of claim 27, wherein:

at least one of said plurality of wall surfaces is non-planar.

32. The device of claim 27, wherein:

at least one of said plurality of wall surfaces is anisotropic.

33. The device of claim 27, wherein:

at least one wall surface from said plurality of wall surfaces is isotropic.

34. The device of claim 27, wherein:

at least one wall surface from said plurality of wall surfaces has a predetermined surface finish.

35. A device comprising:

a first cast non-planar part defining a plurality of channels, each of said channels at least partially bounded by a cast wall comprising a plurality of wall surfaces, a wall surface from said plurality of wall surfaces comprising a first plurality of 3-dimensional micro-features that substantially spatially invertedly replicate an intermediate mold surface of a consumable ceramic intermediate mold, said intermediate mold surface substantially spatially invertedly replicating a parent mold surface formed by a plurality of layers of a metallic foil stack lamination parent mold, said intermediate mold surface defining at least a portion of a periphery of a layer-less volume.

36. The device of claim 35, wherein:

a least one of said channels extends through a predetermined set of cast walls of said first cast non-planar part.

37. The device of claim 35, wherein:

a least one of said channels extends within said first cast non-planar part.

38. The device of claim 35, wherein:

said plurality of channels is interconnected said first cast non-planar part.

39. The device of claim 35, further comprising:

a plurality of protrusions defined by said first cast non-planar part.

40. The device of claim 35, further comprising:

a sub-cavity defined by said first cast non-planar part.

41. The device of claim 35, further comprising:

a second cast part attached to said first cast non-planar part.

42. The device of claim 35, wherein:

said first cast non-planar part is comprised of metal.

43. The device of claim 35, wherein:

at least one wall surface from said plurality of wall surfaces is non-planar.

44. The device of claim 35, wherein:

at least one wall surface from said plurality of wall surfaces is anisotropic.

45. The device of claim 35, wherein:

at least one wall surface from said plurality of wall surfaces is isotropic.

46. The device of claim 35, wherein:

at least one wall surface from said plurality of wall surfaces has a predetermined surface finish.

47. The device of claim 35, wherein:

at least one channel from said plurality of channels has a substantially triangular cross-section.

48. The device of claim 35, wherein:

at least one channel from said plurality of channels has a substantially rectangular cross-section.

49. The device of claim 35, wherein:

at least one channel from said plurality of channels has a substantially square cross-section.

50. The device of claim 35, wherein:

at least one channel from said plurality of channels has a substantially circular cross-section.

51. A method comprising:

forming a part that defines a plurality of channels, each of said channels at least partially bounded by a cast wall comprising a plurality of wall surfaces, a wall surface from said plurality of wall surfaces comprising a first plurality of 3-dimensional micro-features that substantially spatially invertedly replicate an intermediate mold surface of a consumable ceramic intermediate mold insert, said intermediate mold surface substantially spatially invertedly replicating a parent mold surface formed by a plurality of layers of a metallic foil stack lamination parent mold, said intermediate mold surface defining at least a portion of a periphery of a layer-less volume.

52. A method comprising:

molding a part substantially around a consumable ceramic intermediate mold insert, said consumable ceramic non-planar intermediate mold insert consumable to form a plurality of channels in said part, each of said channels at least partially bounded by a cast wall comprising a plurality of wall surfaces, a wall surface from said plurality of wall surfaces comprising a first plurality of 3-dimensional micro-features that substantially spatially invertedly replicate an intermediate mold surface of said consumable ceramic non-planar intermediate mold insert, said intermediate mold surface substantially spatially invertedly replicating a parent mold surface formed by a plurality of layers of a metallic foil stack lamination parent mold, said intermediate mold surface defining at least a portion of a periphery of a layer-less volume.

53. The method of claim 52, further comprising:

consuming said consumable ceramic non-planar intermediate mold insert.

54. The method of claim 52, further comprising:

dissolving at least a portion of said consumable ceramic non-planar intermediate mold insert.

55. The method of claim 52, further comprising:

separating said part from said consumable ceramic non-planar intermediate mold insert.

56. The method of claim 52, wherein:

said part is metallic.

57. The method of claim 52, wherein:

said plurality of channels are interconnected.

58. The method of claim 52, wherein:

a plurality of protrusions extends into at least one channel from said plurality of channels.

59. The method of claim 52, wherein:

at least one wall surface from said plurality of wall surfaces is non-planar.

60. The method of claim 52, wherein:

at least one wall surface from said plurality of wall surfaces is anisotropic.

61. The method of claim 52, wherein:

at least one wall surface from said plurality of wall surfaces is isotropic.

62. The method of claim 52, wherein:

at least one wall surface from said plurality of wall surfaces has a predetermined surface finish.