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US 2015/0021299 A1Published application
Batch Methods of Forming Microscale or Millimeter Scale Structures Using Electro Discharge Machining Alone or In Combination with Other Fabrication Methods
OwnerHeath A. Jensen, Uri Frodis +2inventors
InventorsHeath A. Jensen, Uri Frodis, Christopher G. Wiita, Michael S. Lockard
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Abstract
Embodiments are directed to forming three-dimensional millimeter scale or micro-scale structures from single or multiple sheets or layers of material via electro discharge machining (EDM). In some embodiments, the electrodes are formed by single layer or multi-layer, single material or multi-material deposition processes. In some embodiments single electrodes form a plurality of parts or structures simultaneously. In some embodiments a sacrificial bridging material is used to hold parts together during and after EDM processing.
Claims21
A method for the batch formation of a plurality of micro-scale or millimeter-scale parts, comprising:
- a) obtaining at least one EDM electrode representing a layout of the parts to be formed;
- b) providing a sheet of structural material having a front side and a backside;
- c) locating a bridging sacrificial material on to the backside of the sheet of structural material;
- d) preparing the sheet of structural material and the bridging sacrificial material for EDM processing;
- e) using the at least one EDM electrode to erode or cut selected portions of the sheet so that structural material remains having a configuration of the plurality of parts and such that the plurality of parts remain in place with respect to one another due at least to the presence of the bridging sacrificial material;
- and
- f) removing the bridging sacrificial material.
4 more elements
A method for the batch formation of a plurality of micro-scale or millimeter-scale parts, comprising:
- a) obtaining at least one EDM electrode representing a layout of the parts to be formed;
- b) providing a sheet of structural material having a front side and a backside;
- c) forming at least one multi-material electrochemically fabricated layer on the backside of the sheet of structural material, wherein the at least one multi-material layer comprises at least one structural material and at least one sacrificial material;
- d) preparing the sheet of structural material and at least one backside multi-material layer for EDM processing;
- e) using the at least one EDM electrode to erode or cut selected portions of the sheet so that structural material remains having a configuration of the plurality of parts and such that the plurality of parts remain in place with respect to one another due at least to the presence of the at least one sacrificial material of the at least one backside multi-material layer;
- and
- f) removing the sacrificial material.
4 more elements
A method for the batch formation of a plurality of micro-scale or millimeter-scale parts, comprising:
- a) obtaining at least one EDM electrode representing a layout of the parts to be formed;
- b) providing a sheet of structural material having a front side and a backside;
- c) forming at least one multi-material electrochemically fabricated layer on the backside of the sheet of structural material, wherein the at least one multi-material layer comprises at least one structural material and at least one sacrificial material;
- d) locating a bridging sacrificial material on to the backside of the at least one multi-material layer;
- e) preparing the sheet of structural material, the at least one multi-material layer and the bridging sacrificial material for EDM processing;
- f) using the at least one EDM electrode to erode or cut selected portions of the sheet and multi-material layer so that structural material remains having a configuration of the plurality of parts and such that the plurality of parts remain in place with respect to one another due at least to the presence of the bridging sacrificial material;
- and
- g) removing the sacrificial material forming part of the at least one multi-material layer and removing bridging sacrificial material.
5 more elements
A method for the batch formation of a plurality of micro-scale or millimeter-scale parts, comprising:
- a) obtaining at least one EDM electrode representing a layout of the parts to be formed;
- b) providing a sheet of structural material having a front side and a backside;
- c) forming at least one structural material layer on the backside of the sheet of structural material;
- d) locating a bridging sacrificial material on to the backside of the formed structural material layer;
- e) preparing the sheet of structural material, the formed structural material layer, and the bridging sacrificial material for EDM processing;
- f) using the at least one EDM electrode to erode or cut selected portions of the sheet and the formed structural material layer so that structural material remains having a configuration of the plurality of parts and such that the plurality of parts remain in place with respect to one another due at least to the presence of the bridging sacrificial material;
- and
- g) removing bridging sacrificial material.
5 more elements
A method for the batch formation of a plurality of micro-scale or millimeter-scale parts, comprising:
- a) obtaining at least one EDM electrode representing a layout of the parts to be formed;
- b) providing a sheet of structural material having a front side and a backside;
- c) locating and attaching at least two layers directly or indirectly to the sheet of structural material, wherein the at least two layers are selected from the group consisting of (1) a second sheet layer of structural material, (2) at least one deposited multi-material layer, (3) at least one deposited single material layer, and (4) at least one bridging sacrificial material layer as a final layer opposite to an EDM processing direction;
- wherein the positioning order of stacking of the layers is selected from the group consisting of (1) the at least two layers are below the structural sheet material, (2) the at least two layers are above the structural sheet material layer, (3) a portion of the at least two layers are above the sheet material and a portion of the at least two layers are below the sheet material, (4) multiple layers of at least one type are used and are separated by a layer of another type, (5) multiple layers of at least one type are used and are adjacent to one another.
- d) preparing the sheet of structural material and the located and attached layers for EDM processing;
- e) using the at least one EDM electrode to erode or cut selected portions of the sheet and the at least two other layers so that structural material remains having a configuration of the plurality of parts and such that the plurality of parts remain in place with respect to one another due at least to the presence of a sacrificial material;
- and
- f) removing sacrificial material.
5 more elements
Dependencies are inferred from the claim text.