Methods for manufacturing three-dimensional devices and devices created thereby

• US 8,062,023 B2
• Filed: 06/13/2008
• Issued: 11/22/2011
• Est. Priority Date: 06/05/2001
• Status: Expired due to Term

• Current Assignee: Raytheon Technologies Corporation d/b/a RTX
• Original Assignee: Mikro Systems, Inc.
• Inventors: Fraser, Iain, Appleby, Michael P., Atkinson, James E.
• Primary Examiner(s): Nguyen; Khanh P
• Assistant Examiner(s): Patel; Vishal I
• Application Number:
  US12/138,472
• Publication Number:
  US 20090084933A1
• Time in Patent Office: 1,257 Days
• Field of Search: 425/470, 425/DIG.58, 425/DIG.30, 156/245
• US Class Current: 425/470
• 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 first cast grid defining a plurality of spaces, each space bounded by at least one cast wall comprising a plurality of wall surfaces;

for each cast wall, a wall surface from said plurality of wall 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 wall surfaces for each cast wall defining a periphery of a layer-less volume;

said plurity of layers aligned substantially perpendicular to a direction in which said first cast grid removable from said metallic foil stack lamination parent mold with damage to neither said first cast grid nor said metallic foil stack lamination parent mold.

2. The device of claim 1, further comprising:

a channel extending through a predetermined set of cast walls of said cast grid.

3. The device of claim 1, further comprising:

a second cast grid attached to said first cast grid.

4. The device of claim 1, further comprising:

a cast face sheet integral with said first cast grid.

5. The device of claim 1, further comprising:

a non-planar cast face sheet integral with said first cast grid.

6. The device of claim 1, further comprising:

a non-planar cast face sheet adapted to be attached to said first cast grid.

7. The device of claim 1, further comprising:

an attachment feature adapted to attach said first cast grid to a distinct part.

8. The device of claim 1, further comprising:

an integral attachment feature adapted to attach said first cast grid to a distinct part.

9. The device of claim 1, further comprising:

an attachment feature adapted to attach said first cast grid to a distinct part via an interference fit.

10. The device of claim 1, further comprising:

a stilt adapted to attach said first cast grid to a distinct part.

11. The device of claim 1, further comprising:

a protrusion adapted to snapably attach said first cast grid to a distinct part.

12. The device of claim 1, further comprising:

a hole adapted to receivably attach said first cast grid to a distinct part.

13. The device of claim 1, further comprising:

an indentation adapted to receivably attach said first cast grid to a distinct part.

14. The device of claim 1, further comprising:

a lip adapted to attach said first cast grid to a distinct part.

15. The device of claim 1, further comprising:

a groove adapted to receivably attach said first cast grid to a distinct part.

16. The device of claim 1, further comprising:

an alignment feature adapted to align said first cast grid with a distinct part.

17. The device of claim 1, further comprising:

a separation feature adapted to separate said first cast grid from a distinct part.

18. The device of claim 1, further comprising:

a separation feature adapted to separate said first cast grid from a distinct part by a predetermined distance.

19. The device of claim 1, wherein:

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

20. The device of claim 1, wherein:

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

21. The device of claim 1, wherein:

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

22. The device of claim 1, wherein:

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

23. The device of claim 1, wherein:

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

26. The device of claim 1, wherein:

for at least one of said plurality of layers of metallic foil laminations, a depth of etching of a top side of said layer is not equal to a depth of etching of a bottom side of said layer.

27. The device of claim 1, wherein:

a sidewall defined by said metallic foil stack lamination parent mold is isotropic.

28. The device of claim 1, wherein:

a first sidewall defined by said metallic foil stack lamination parent mold is isotropic with respect to a second sidewall defined by said metallic foil stack lamination parent mold.

29. The device of claim 1, wherein:

a first sidewall defined by said metallic foil stack lamination parent mold is anisotropic with respect to a second sidewall defined by said metallic foil stack lamination parent mold.

30. The device of claim 1, wherein:

said first cast grid is comprised of a flexible silicone material.

31. The device of claim 1, wherein:

at least one of said plurality of wall surfaces comprises a plurality of projections that has an average dimension measured perpendicular to said at least one wall surface of approximately 0.025 microns to approximately 0.1 microns.

32. The device of claim 1, wherein:

at least one of said plurality of 3-dimensional micro-features has a dimension measuring approximately 0.25 microns to approximately 0.5 microns.

33. The device of claim 1, wherein:

said first cast grid is comprised of a flexible silicone material and is adapted to serve as a flexible silicone mold for a second cast grid, said second cast grid removable from said first cast grid with damage to neither said first cast grid nor said second cast grid.

24. A device comprising:

a first cast grid defining a plurality of spaces, each of said spaces bounded by at least one cast wall comprising a plurality of wall surfaces;

for each cast wall, a wall surface from said plurality of wall 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 wall surfaces for each cast wall defining a periphery of a layer-less volume;

said plurity of layers aligned substantially perpendicularly to a direction in which said first cast grid removable from said metallic foil stack lamination parent mold with damage to neither said first cast grid nor said metallic foil stack lamination parent mold.

25. A method comprising:

attaching a first cast grid to a distinct part, said first cast grid defining a plurality of spaces, each of said spaces bounded by at least one cast wall comprising a plurality of wall surfaces, for each cast wall, a wall surface from said plurality of wall 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 wall surfaces for each cast wall defining a periphery of a layer-less volume, said plurity of layers aligned substantially perpendicularly to a direction in which said first cast grid is removable from said metallic foil stack lamination parent mold with damage to neither said first cast grid nor said metallic foil stack lamination parent mold.