Methods for manufacturing three-dimensional devices and devices created thereby

• US 7,410,606 B2
• Filed: 06/05/2002
• Issued: 08/12/2008
• Est. Priority Date: 06/05/2001
• Status: Active Grant

• Current Assignee: Rtx Corporation
• Original Assignee: Iain Fraser, James E. Atkinson, Michael P. Appleby
• Inventors: Fraser, Iain, Appleby, Michael P., Atkinson, James E.
• Primary Examiner(s): Tentoni; Leo B
• Application Number:
  US10/479,335
• Publication Number:
  US 20040156478A1
• Time in Patent Office: 2,260 Days
• Field of Search: 264/219, 264/318, 249/117, 249/134, 249/135
• US Class Current: 264/219
• 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

A process of making a casting includes the steps of designing a mold (1010), fabricating the layers (or laminations) of the mold (1020), stacking and assembling the laminations into a mold (1030), producing a casting (1060) and demolding the casting (1070). If necessary, a derived mold can be made (1040, 1050) prior to producing the casing (1060).

Claims

1. A method of forming a casting, comprising:

filling a mold having a stacked plurality of lithographically-derived micro-machined metallic foil layers with a first casting material to form a first cast product having an aspect ratio of greater than 10;

1, the stacked plurality of lithographically-derived micro-machined metallic foil layers defining a protruding undercut; and

demolding the first cast product from the mold, said first cast product comprising a plurality of product surfaces that define a periphery of a layer-less volume of said first cast product, a product surface from said plurality of product surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by said stacked plurality of metallic foil layers.

2. The method of claim 1, further comprising providing the mold.

3. The method of claim 1, further comprising, for each of the stacked plurality of lithographically-derived micro-machined layers, designing a feature associated with the layer.

4. The method of claim 1, further comprising designing a feature associated with all of the stacked plurality of lithographically-derived micro-machined layers of the mold.

5. The method of claim 1, further comprising micro-machining each of the stacked plurality of lithographically-derived micro-machined layers.

6. The method of claim 1, further comprising, for each of the stacked plurality of lithographically-derived micro-machined layers, micro-machining a feature associated with the layer.

7. The method of claim 1, further comprising micro-machining a feature associated with all of the stacked plurality of lithographically-derived micro-machined layers.

8. The method of claim 1, further comprising stacking the stacked plurality of lithographically-derived micro-machined layers.

9. The method of claim 1, further comprising aligning the stacked plurality of lithographically-derived micro-machined layers.

10. The method of claim 1, further comprising bonding the stacked plurality of lithographically-derived micro-machined layers.

11. The method of claim 1, further comprising clamping the stacked plurality of lithographically-derived micro-machined layers.

12. The method of claim 1, further comprising securing the stacked plurality of lithographically-derived micro-machined layers.

13. The method of claim 1, further comprising affixing the stacked plurality of lithographically-derived micro-machined layers.

14. The method of claim 1, further comprising fabricating the mold.

15. The method of claim 1, further comprising allowing the first casting material to solidify to form the first cast product.

16. The method of claim 1, further comprising surrounding the first cast product with a second casting material.

17. The method of claim 1, further comprising surrounding the first cast product with a second casting material and allowing the second casting material to solidify into a second cast product.

18. The method of claim 1, further comprising surrounding the first cast product with a second casting material and allowing the second casting material to solidify into a nonplanar second cast product.

19. The method of claim 1, further comprising forming the first cast product into a non-planar shape.

20. The method of claim 1, further comprising forming the first cast product into a non-planar shape and surrounding the formed first cast product with a second casting material and allowing the second casting material to solidify into a nonplanar second cast product.

21. The method of claim 1, further comprising surrounding the first cast product with a second casting material and demolding a second cast product formed from the second casting material.

22. The method of claim 1, wherein the first casting material comprises a flexible polymer.

23. The method of claim 1, wherein the first casting material comprises an elastomer.

24. The method of claim 1, wherein the first casting material comprises silicone rubber.

25. The method of claim 1, wherein the stacked plurality of lithographically-derived micro-machined layers define a cavity having a protruding undercut.

26. The method of claim 1, wherein the stacked plurality of lithographically-derived micro-machined layers define a plurality of cavities therein.

27. The method of claim 1, further comprising positioning an insert into a cavity defined by the stacked plurality of lithographically-derived micro-machined layers.

28. The method of claim 1, further comprising positioning an insert into a cavity defined by the stacked plurality of lithographically-derived micro-machined layers, the insert occupying only a portion of the cavity.

29. The method of claim 1, further comprising positioning an insert into a cavity defined by the stacked plurality of lithographically-derived micro-machined layers prior to said filling the mold with the first casting material.

30. The method of claim 1, further comprising positioning a lithographically-derived micro-machined insert into a cavity defined by the stacked plurality of lithographically-derived micro-machined layers prior to said filling the mold with the first casting material.

31. The method of claim 1, wherein the first cast product has an aspect ratio greater than 100:

1.

32. The method of claim 1, further comprising surrounding the first cast product with a second casting material and demolding a second cast product formed from the second casting material, the second cast product having an aspect ratio greater than 100:

1.

33. The method of claim 1, wherein a cavity defined by the stacked plurality of lithographically-derived micro-machined layers has an aspect ratio greater than 100:

1.

34. The method of claim 1, wherein the first cast product is an end product.

35. The method of claim 1, further comprising surrounding the first cast product with a second casting material and demolding a second cast product formed from the second casting material, the second cast product being an end product.

36. The method of claim 1, wherein the first cast product is attached to a substrate.

37. The method of claim 1, wherein the first cast product is a free-standing structure.

38. A method of forming a casting, comprising:

filling a mold having a stacked plurality of lithographically-derived micro-machined metallic foil layers with a first casting material to form a first cast product having an aspect ratio of greater than 10;

1, the stacked plurality of lithographically-derived micro-machined metallic foil layers defining a protruding undercut; and

demolding the first cast product from the mold, the first cast product reflecting the protruding undercut, said first cast product comprising a plurality of product surfaces that define a periphery of a layer-less volume of said first cast product, a product surface from said plurality of product surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by said stacked plurality of metallic foil layers.

39. A method of fabricating a stack lamination mold, comprising:

lithographically micro-machining each of a plurality of metallic foil layers; and

assembling the plurality of layers into a stack that defines a protruding undercut and an aspect of greater than 10;

1.

40. A lithographically-derived micro-machined metallic foil stack lamination mold that defines a protruding undercut and that defines an aspect ratio of greater than 10:

1.

41. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40, wherein said mold is a positive replication of a predetermined end product.

42. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40, wherein said mold is a negative replication of a predetermined end product.

43. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40, wherein said mold defines at least one feature having an aspect ratio of greater than 10:

1.

44. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40, wherein said mold defines at least one feature having an aspect ratio of greater than 15:

1.

45. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40, wherein said mold defines at least one feature having an aspect ratio of greater than 20:

1.

46. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40, wherein said mold defines at least one feature having an aspect ratio of greater than 25:

1.

47. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40, wherein said mold defines at least one feature having an aspect ratio of greater than 30:

1.

48. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40, wherein said mold defines at least one feature having an aspect ratio of greater than 40:

1.

49. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40, wherein said mold defines at least one feature having an aspect ratio of greater than 50:

1.

50. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40, wherein said mold defines at least one feature having an aspect ratio of greater than 75:

1.

51. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40, wherein said mold defines at least one feature having an aspect ratio of greater than 100:

1.

52. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40, wherein said mold defines at least one feature having an aspect ratio of greater than 150:

1.

53. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40, wherein said mold defines at least one feature having an aspect ratio of greater than 200:

1.

54. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40, wherein said mold defines at least one feature having an aspect ratio of greater than 250:

1.

55. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40, wherein said mold defines at least one feature having an aspect ratio of greater than 300:

1.

56. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40, wherein said mold defines at least one feature having an aspect ratio of greater than 400:

1.

57. A metallic foil stack lamination mold that defines a protruding undercut and an aspect ratio of greater than 10:

1.

58. A metallic foil stack lamination mold that defines a cavity having a protruding undercut and an aspect ratio of greater than 10:

1.

59. A mold derived from a metallic foil stack lamination mold, said derived mold defining a cavity therein, a protruding undercut, and a feature having an aspect ratio greater than 10:

1, said derived mold comprising a plurality of surfaces that define a periphery of a layer-less volume of said derived mold, a surface from said plurality of surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a stack lamination mold surface formed by a stacked plurality of metallic foil layers comprised by said stack lamination mold.

60. A mold derived from a metallic foil stack lamination mold, said derived mold defining a protruding undercut and an aspect ratio of greater than 10:

1, said derived mold comprising a plurality of surfaces that define a periphery of a layer-less volume of said derived mold, a surface from said plurality of surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a stack lamination mold surface formed by a stacked plurality of metallic foil layers comprised by said stack lamination mold.

61. A mold derived from a metallic foil stack lamination mold, said derived mold defining a cavity having a protruding undercut and an aspect ratio of greater than 10:

1, said derived mold comprising a plurality of surfaces that define a periphery of a layer-less volume of said derived mold, a surface from said plurality of surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a stack lamination mold surface formed by a stacked plurality of metallic foil layers comprised by said stack lamination mold.

62. A method of forming a casting, comprising:

filling a mold having a stacked plurality of lithographically-derived micro-machined layers with a first casting material to form a first cast product having an aspect ratio of greater than 10;

1, the stacked plurality of lithographically-derived micro-machined layers defining a protruding undercut; and

demolding the first cast product from the mold, such that the mold is not substantially damaged, said first cast product comprising a plurality of component surfaces that define a periphery of a layer-less volume of said first cast product, 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 said stacked plurality of layers.

63. A method of forming a casting, comprising:

filling a mold having a stacked plurality of lithographically-derived micro-machined layers with a first casting material to form a first cast product having an aspect ratio of greater than 10;

1, the stacked plurality of lithographically-derived micro-machined layers defining a protruding undercut; and

demolding the first cast product from the mold such that the mold is not substantially damaged, the first cast product reflecting the protruding undercut, said first cast product comprising a plurality of component surfaces that define a periphery of a layer-less volume of said first cast product, 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 said stacked plurality of layers.