Methods for Manufacturing Three-Dimensional Devices and Devices Created Thereby

• US 20090272874A1
• Filed: 07/16/2009
• Published: 11/05/2009
• Est. Priority Date: 06/05/2001
• Status: Active Grant

• Current Assignee: Rtx Corporation
• Original Assignee: United Technologies Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Inventors: Fraser, Iain, Appleby, Michael P., Atkinson, James E.
• Granted Patent: US 10,189,184 B2
• Time in Patent Office: Days
• US Class Current: 249/83
• 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.

Claims

1. A device comprising:

a cast component, said cast component comprising a plurality of component surfaces, a component surface from said plurality of component surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed 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 component surfaces defining a periphery of a layer-less volume; and

an electrically conductive feature extending through and/or across a portion of said cast component.

2. The device of claim 1, further comprising:

a microelectronic component integrated with said electrically conductive feature.

3. The device of claim 1, further comprising:

a microelectronic component electrically coupled to said electrically conductive feature.

4. The device of claim 1, further comprising:

an integrated circuit electrically coupled to said electrically conductive feature.

5. The device of claim 1, further comprising:

a detector electrically coupled to said electrically conductive feature.

6. The device of claim 1, further comprising:

a microwell electrically coupled to said electrically conductive feature.

7. The device of claim 1, wherein:

said electrically conductive feature comprises at least one electrically conductive layer.

8. The device of claim 1, wherein:

said electrically conductive feature comprises at least one electrically conductive coating.

9. The device of claim 1, wherein:

said electrically conductive feature comprises at least one electrically conductive plating.

10. The device of claim 1, wherein:

said electrically conductive feature comprises at least one electrically conductive path.

11. The device of claim 1, wherein:

said cast component comprises an integrated circuit.

12. The device of claim 1, wherein:

said cast component comprises a detector.

13. The device of claim 1, wherein:

said cast component comprises a plurality of microwells.

14. The device of claim 1, wherein:

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

15. The device of claim 1, wherein:

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

16. The device of claim 1, wherein:

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

17. The device of claim 1, wherein:

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

18. The device of claim 1, wherein:

said cast component comprises silica, silicon carbide, alumina, and/or zirconium oxide.

19. A device comprising:

a cast component, said cast component comprising a plurality of component surfaces, a component surface from said plurality of component surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed 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 component surfaces defining a periphery of a layer-less volume, wherein said cast component comprises silicon carbide.

20. The device of claim 19, further comprising:

at least one channel defined by said cast component.

21. The device of claim 19, further comprising:

a plurality of channels extending within said cast component.

22. The device of claim 19, further comprising:

an interconnected plurality of channels extending within said cast component.

23. The device of claim 19, further comprising:

a plurality of protrusions defined by said cast component.

24. The device of claim 19, further comprising:

a sub-cavity defined by said cast component.

25. The device of claim 19, further comprising:

a second cast component attached to said cast component.

26. The device of claim 19, wherein:

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

27. The device of claim 19, wherein:

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

28. The device of claim 19, wherein:

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

29. The device of claim 19, wherein:

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

30. A device comprising:

a first cast component 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 an 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, said first cast component comprising silicone carbide.

31. A lithographically-derived micro-machined metallic foil stack lamination mold that defines a protruding undercut, said lithographically-derived micro-machined metallic foil stack lamination mold comprising silicon carbide.

32. A device comprising:

a cast component, said cast component comprising a plurality of component surfaces, a predetermined component surface from said plurality of component surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed 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 component surfaces defining a periphery of a layer-less volume, said predetermined component surface having a predetermined surface condition.

33. The device of claim 32, wherein:

said predetermined component surface comprises an electro-plating.

34. The device of claim 32, wherein:

said predetermined component surface comprises a deposition.

35. The device of claim 32, wherein:

said predetermined component surface comprises a controlled-release chemical.

36. The device of claim 32, wherein:

said predetermined component surface comprises a radioactive element.

37. The device of claim 32, wherein:

said predetermined component surface comprises a predetermined chemical.

38. The device of claim 32, wherein:

said predetermined component surface is radio-opaque.

39. The device of claim 32, wherein:

said predetermined component surface is biocompatible.

40. The device of claim 32, wherein:

said predetermined component surface is biosorbable.

41. The device of claim 32, wherein:

said predetermined component surface is biodissolvable.

42. The device of claim 32, wherein:

said cast component demonstrates shape memory.

43. The device of claim 32, further comprising:

at least one channel defined by said cast component.

44. The device of claim 32, further comprising:

an interconnected plurality of channels extending within said cast component.

45. The device of claim 32, further comprising:

a plurality of protrusions defined by said cast component.

46. The device of claim 32, further comprising:

a sub-cavity defined by said cast component.

47. The device of claim 32, further comprising:

a second cast component attached to said cast component.

48. The device of claim 32, wherein:

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

49. The device of claim 32, wherein:

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

50. The device of claim 32, wherein:

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

51. The device of claim 32, wherein:

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

52. The device of claim 32, wherein:

said cast component comprises a microwell.