Rapid Prototyping of Microstructures Using a Cutting Plotter

A micro knife plotter device for making microstructures, comprising:

• a) a feed mechanism for feeding a film through the plotter device;
• b) a knife head with a knife blade, disposed adjacent the feed mechanism, and configured to move laterally across the film as the film is fed through the plotter device;
• c) a motor and control system, coupled to the knife head, for selectively moving the knife head in relation to the film;
• and
• d) the control system and the knife head having an addressable positioning resolution less than approximately 10 μm.

A method for making a microstructure, comprising:

• a) providing a film with a thickness between approximately 20-100 μm and disposed on a release liner;
• b) feeding the film through a cutting plotter having a controller and an addressable resolution less than approximately 10 μm;
• c) cutting the film with a knife blade of the cutting plotter to form a pattern;
• d) weeding unwanted portions from the cut film to form an unweeded layer of film;
• and
• e) peeling the pattern from the release liner;
• and
• f) transferring the pattern to a substrate.