Methods for manufacturing three-dimensional devices and devices created thereby
First Claim
1. A method, comprising:
- demolding a silicone first cast product from a mold without damage to either the first cast product or the mold, the mold comprising a stacked plurality of micro-machined metallic foil layers that define a protruding undercut and a feature, the first cast product reflecting the protruding undercut and the feature, the protruding undercut aligned substantially perpendicularly to a direction in which the first cast product is removable from the mold without damage to the first cast product and without damage to the mold,wherein;
contact between the protruding undercut and a surface of the first cast product is released via a force applied in the direction;
the surface is spatially reflective of the protruding undercut and located within a plane that is perpendicular to the direction; and
a thickness of each micro-machined metallic foil layer of the mold from the plurality of micro-machined metallic foil layers is between 2 micrometers and 100 micrometers.
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Accused Products
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.
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Citations
19 Claims
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1. A method, comprising:
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demolding a silicone first cast product from a mold without damage to either the first cast product or the mold, the mold comprising a stacked plurality of micro-machined metallic foil layers that define a protruding undercut and a feature, the first cast product reflecting the protruding undercut and the feature, the protruding undercut aligned substantially perpendicularly to a direction in which the first cast product is removable from the mold without damage to the first cast product and without damage to the mold, wherein; contact between the protruding undercut and a surface of the first cast product is released via a force applied in the direction; the surface is spatially reflective of the protruding undercut and located within a plane that is perpendicular to the direction; and a thickness of each micro-machined metallic foil layer of the mold from the plurality of micro-machined metallic foil layers is between 2 micrometers and 100 micrometers. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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Specification