Manufacturing of a metal mold for replicating a component having a predetermined three-dimensional shape

A method of replicating a component having a predetermined three-dimensional shape, the method comprising:

• (a) fabricating a glass-based mold by using a moldable nanocomposite comprising an organic binder and glass particles dispersed therein, the glass-based mold having the predetermined three-dimensional shape and being obtained as follows:
• (i) shaping the moldable nanocomposite into the predetermined three-dimensional shape before, during and/or after hardening of the organic binder, thereby obtaining a primary structure;
• (ii) debinding the primary structure obtained in step (i) by removing the organic binder, thereby obtaining a secondary structure, the secondary structure having cavities formed therein;
• (iii) optionally filling the cavities of the secondary structure obtained in step (ii) with at least one glass-forming precursor;
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• (iv) sintering the secondary structure obtained in step (ii) optionally filled with at least one glass-forming precursor in step (iii), thereby obtaining the glass-based mold;
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• (b) replicating the glass-based mold obtained in step (a) by melting a metal inside the glass-based mold or by melting a metal outside the glass-based mold and pouring it onto or into the glass-based mold, followed by cooling, or by pressing the glass-based mold into a malleable metal substrate, thereby obtaining the metal mold for replicating the component, the metal mold having the predetermined three-dimensional shape inverted;
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• (c) replicating the component using the metal mold, wherein the glass particles of the moldable nanocomposite comprise a first type of glass particles having a diameter ranging from 5 nm to 500 nm.