Methods for manufacturing three-dimensional devices and devices created thereby

• US 9,208,916 B2
• Filed: 06/18/2008
• Issued: 12/08/2015
• 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: Appleby, Michael P., Fraser, Iain, Atkinson, James E.
• Primary Examiner(s): SANDERS, JAMES M
• Application Number:
  US12/141,455
• Publication Number:
  US 20080246180A1
• Time in Patent Office: 2,729 Days
• Field of Search: 249/117, 249/120, 249/122, 249/126, 249/134, 249/135, 249/140, 249/156, 249/157, 425464-470, 425/DIG.58, 264219-221, 264/224, 264/318, 430322-323
• US Class Current: 1/1
• 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.

Claims

1. A system 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; and

a parent mold that defines a cavity configured to mold said first consumable ceramic non-planar mold;

wherein;

said cavity is substantially filled by said first consumable ceramic non-planar mold;

said cavity define a single demolding opening for said first consumable ceramic non-planar mold;

said demolding opening defines a demolding direction in which said first consumable ceramic non-planar mold is removable via said demolding opening from said cavity of said parent mold with damage to neither said first consumable ceramic non-planar mold nor said parent mold;

said cavity defines a first cavity cross-sectional area that extends solely within a first cavity plane that is oriented perpendicularly to said demolding direction;

said cavity defines a second cavity cross-sectional area that extends solely within a second cavity plane that is oriented perpendicularly to said demolding direction;

said first cavity cross-sectional area is smaller than said second cavity cross-sectional area; and

said first cavity plane is closer to said demolding opening than said second cavity plane.

2. The system 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 system of claim 1, further comprising:

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

4. The system of claim 1, further comprising:

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

5. The system of claim 1, further comprising:

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

6. The system of claim 1, further comprising:

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

7. The system of claim 1, wherein:

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

8. The system of claim 1, wherein:

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

9. The system of claim 1, wherein:

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

10. The system of claim 1, wherein:

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

11. The system of claim 1, wherein:

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

12. The system of claim 1, wherein:

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

13. The system of claim 1, wherein:

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

14. The system of claim 1, wherein:

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

15. The system of claim 1, wherein:

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

16. The system of claim 1, wherein:

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

17. A system 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; and

a parent mold that defines a cavity configured to mold said first consumable ceramic non-planar mold insert;

wherein;

said cavity is substantially filled by said first consumable ceramic non-planar mold insert;

said cavity defines a single molding opening for said first consumable ceramic non-planar mold insert;

said demolding opening defines a demolding direction in which said first consumable ceramic non-planar mold insert is removable via said demolding opening from said cavity of said parent mold with damage to neither said first consumable ceramic non-planar mold insert nor said parent mold;

said cavity defines a first cavity cross-sectional area that extends solely within a first cavity plane that is oriented perpendicularly to said demolding direction;

said cavity defines a second cavity cross-sectional area that extends solely within a second cavity plane that is oriented perpendicularly to said demolding direction;

said first cavity cross-sectional area is smaller than said second cavity cross-sectional area; and

said first cavity plane is closer to said demolding opening than said second cavity plane.

18. The system of claim 17, wherein:

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

19. The system of claim 17, wherein:

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

20. The system of claim 17, wherein:

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

21. The system of claim 17, wherein:

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

22. The system of claim 17, wherein:

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

23. The system of claim 17, wherein:

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

24. The system of claim 17, wherein:

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

25. A system comprising:

a first consumable ceramic non-planar mold insert defined by at least one cast wall comprising a plurality of wall surfaces; and

a parent mold that defines a cavity configured to mold said first consumable ceramic non-planar mod insert;

wherein;

said cavity is substantially filled by said first consumable ceramic non-planar mold insert;

said cavity defines a single molding opening or said first consumable ceramic non-planar mold insert;

said demolding opening defines a demolding direction in which said first consumable ceramic non-planar mold insert is removable via said demolding opening from said cavity of said parent mold with damage to neither said first consumable ceramic non-planar mold insert nor said intermediate mold;

said cavity defines a first cavity cross-sectional area that extends solely within a first cavity plane that is oriented perpendicularly to said demolding direction;

said cavity defines a second cavity cross-sectional area that extends solely within a second cavity plane that is oriented perpendicularly to said demolding direction;

said first cavity cross-sectional area is smaller than said second cavity cross-sectional area; and

said first cavity plane is closer to said demolding opening than said second cavity plane.

26. The system claim 25, wherein:

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

27. The system claim 25, wherein:

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

28. The system of claim 25, wherein:

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

29. The system of claim 25, wherein:

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

30. The system of claim 25, wherein:

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