Method and apparatus for making printed circuit boards

In a method of making a printed circuit board including a planar substrate having thereon a desired electrical circuit with metallized solder lands thereof disposed out of the plane of the substrate, the steps of making a three dimensional male tool, comprising:

• coating a three dimensional female predecessor master tool having out of plane portions corresponding substantially to the out of plane solder lands of the printed circuit board, with a weak adhesion material;
• depositing a thin layer of metallic material on the out of plane portions of the coated female predecessor master tool;
• forming a backing on the deposited metallic material to help rigidify it;
• separating said thin layer of metallic material from said female predecessor master tool to form the resulting three dimensional male mold tool, said male mold tool having metallized out of plane portions complementary shaped relative to the out of plane solder lands of the printed circuit board.

A method of making a metallized plastic member, comprising:

• coating a mold member with a thin layer of weak adhesion material;
• electroplating to said mold member a thin layer of metallic material;
• coating one surface of said thin layer of metallic material with a strong adhesion promoting substance;
• engaging said mold member with another mold member to form a two part mold with a cavity disposed therebetween;
• filling substantially said cavity with a sufficient quantity of plastic material to form a plastic member having a desired configuration;
• whereby said thin layer of metallic material is bonded adhesively to said plastic member to form the metallized plastic member.

A method of making a metallized plastic member comprising:

• coating a mold member with a thin layer of weak adhesion material;
• electroplating to the coated mold member a thin layer of metallic material;
• coating one surface of said thin layer of metallic material with a strong adhesion promoting substance;
• engaging said mold member with another mold member to form a two part mold with a cavity disposed therebetween;
• filling substantially said cavity with a sufficient quantity of plastic material to form a plastic member having a desired configuration;
• whereby said thin layer of metallic material is bonded adhesively to said plastic member to form the metallized plastic member;
• and
• wherein said step of coating with a thin layer of weak adhesion material includes bathing said mold member in a weak adhesion solution of water and copper sulfate.

A method of making a metallized plastic member comprising:

• coating a mold member with a thin layer of weak adhesion material;
• electroplating to the coated mold member a thin layer of metallic material;
• coating one surface of said thin layer of metallic material with a strong adhesion promoting substance;
• engaging said mold member with another mold member to form a two part mold with a cavity disposed therebetween;
• filling substantially said cavity with a sufficient quantity of plastic material to form a plastic member having a desired configuration;
• whereby said thin layer of metallic material is bonded adhesively to said plastic member to form the metallized plastic member;
• and
• wherein said step of coating with a thin layer of weak adhesion material includes spraying said mold member with a thin coating of graphite.

A method of making a metallized plastic member comprising:

• coating a mold member with a thin layer of weak adhesion material;
• electroplating to the coated mold member a thin layer of metallic material;
• coating one surface of said thin layer of metallic material with a strong adhesion promoting substance;
• engaging said mold member with another mold member to form a two part mold with a cavity disposed therebetween;
• filling substantially said cavity with a sufficient quantity of plastic material to form a plastic member having a desired configuration;
• whereby said thin layer of metallic material is bonded adhesively to said plastic member to form the metallized plastic member;
• and
• wherein said step of coating with a thin layer of metallic material includes vacuum metallizing said mold member with a thin coat of metallic material.