Polycrystalline complex-shaped mesoscale components

Abstract

A polycrystalline mesoscale component is provided that has an overall length L divided into multiple segments with a second segment extending from a first segment at a nonlinear angle. The first segment has a first segment height H1 and a first segment thickness T1, while the second segment has a second segment height H2 and a second segment thickness T1, with the lesser of H1 and H2 defining a minimum segment height Hmin and the lesser of T1 and T2 defining a minimum segment thickness Tmin. The resultant component has a ratio of L:Hmin:Tmin of 20-80:1:0.5-10 where Hmin is between 5 and 500 microns. In specific instances, the nonlinear angle is acute, the multiple segments are rectilinear in cross section, and a segment thickness has an edge resolution of between 0.1 and 2 microns. A process for forming a polycrystalline mesoscale component is provided that includes filling a mold cavity formed in a photoresist with a mold fill. The mold fill includes a slurry of particles of ceramic, metal, or a combination thereof in a polymerizable monomer in an amount to form a polymer that imparts strength to the mold fill. Thereafter the photoresist is removed and the gel cast mold fill is heated to remove the polymer and form the polycrystalline sintered mesoscale component. In a particular embodiment, the mold fill after removal of the photoresist is heated in contact with a second mold fill to form a composite component with a sintered interface between the mold fill and the second mold fill.

Dependencies are inferred from the claim text.