Methods of forming parts using laser machining
First Claim
1. A method of forming a plurality of laterally displaced micro-scale or millimeter-scale structure, comprising:
- a) providing at least one sheet of structural material having a front side and a backside and extending laterally in a plane of the sheet;
b) locating a bridging sacrificial material directly or indirectly on the backside of the at least one sheet of structural material;
c) using a laser beam to cut completely through the at least one sheet from the front side to the backside along cutting paths to define cross-sectional boundaries of each of the plurality of laterally displaced structures without cutting completely through the bridging sacrificial material along the cutting paths for the plurality of structures, wherein individual structures have cross-sectional configurations defined by the cross-sectional boundaries created by cutting using the laser beam; and
d) after the defining of the cross-sectional boundaries of the plurality of laterally displaced structures, releasing the laterally displaced structures from one another, wherein the releasing comprises removing the bridging sacrificial material.
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Abstract
Embodiments are directed to the formation micro-scale or millimeter scale structures or methods of making such structures wherein the structures are formed from at least one sheet structural material and may include additional sheet structural materials or deposited structural materials wherein all or a portion of the patterning of the structural materials occurs via laser cutting. In some embodiments, selective deposition is used to provide a portion of the patterning. In some embodiments the structural material or structural materials are bounded from below by a sacrificial bridging material (e.g. a metal) and possibly from above by a sacrificial capping material (e.g. a metal).
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Citations
20 Claims
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1. A method of forming a plurality of laterally displaced micro-scale or millimeter-scale structure, comprising:
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a) providing at least one sheet of structural material having a front side and a backside and extending laterally in a plane of the sheet; b) locating a bridging sacrificial material directly or indirectly on the backside of the at least one sheet of structural material; c) using a laser beam to cut completely through the at least one sheet from the front side to the backside along cutting paths to define cross-sectional boundaries of each of the plurality of laterally displaced structures without cutting completely through the bridging sacrificial material along the cutting paths for the plurality of structures, wherein individual structures have cross-sectional configurations defined by the cross-sectional boundaries created by cutting using the laser beam; and d) after the defining of the cross-sectional boundaries of the plurality of laterally displaced structures, releasing the laterally displaced structures from one another, wherein the releasing comprises removing the bridging sacrificial material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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Specification