Methods for manufacturing three-dimensional devices and devices created thereby
OwnerMichael P. Appleby, Iain Fraser +1inventors
InventorsMichael P. Appleby, Iain Fraser, James E. Atkinson
Life of this patent
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Abstract
A process of making a casting includes the steps of designing a mold (1010), fabricating the layers (or laminations) of the mold (1020), stacking and assembling the laminations into a mold (1030), producing a casting (1060) and demolding the casting (1070). If necessary, a derived mold can be made (1040, 1050) prior to producing the casing (1060).
Claims63
A method of forming a casting, comprising:
- filling a mold having a stacked plurality of lithographically-derived micro-machined metallic foil layers with a first casting material to form a first cast product having an aspect ratio of greater than 10:1, the stacked plurality of lithographically-derived micro-machined metallic foil layers defining a protruding undercut;
- and
- demolding the first cast product from the mold, said first cast product comprising a plurality of product surfaces that define a periphery of a layer-less volume of said first cast product, a product surface from said plurality of product surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by said stacked plurality of metallic foil layers.
A method of forming a casting, comprising:
- filling a mold having a stacked plurality of lithographically-derived micro-machined metallic foil layers with a first casting material to form a first cast product having an aspect ratio of greater than 10:1, the stacked plurality of lithographically-derived micro-machined metallic foil layers defining a protruding undercut;
- and
- demolding the first cast product from the mold, the first cast product reflecting the protruding undercut, said first cast product comprising a plurality of product surfaces that define a periphery of a layer-less volume of said first cast product, a product surface from said plurality of product surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by said stacked plurality of metallic foil layers.
A method of fabricating a stack lamination mold, comprising:
- lithographically micro-machining each of a plurality of metallic foil layers;
- and
- assembling the plurality of layers into a stack that defines a protruding undercut and an aspect of greater than 10:1.
A lithographically-derived micro-machined metallic foil stack lamination mold that defines a protruding undercut and that defines an aspect ratio of greater than 10:1.
A metallic foil stack lamination mold that defines a protruding undercut and an aspect ratio of greater than 10:1.
A metallic foil stack lamination mold that defines a cavity having a protruding undercut and an aspect ratio of greater than 10:1.
A mold derived from a metallic foil stack lamination mold, said derived mold defining a cavity therein, a protruding undercut, and a feature having an aspect ratio greater than 10:1, said derived mold comprising a plurality of surfaces that define a periphery of a layer-less volume of said derived mold, a surface from said plurality of surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a stack lamination mold surface formed by a stacked plurality of metallic foil layers comprised by said stack lamination mold.
A mold derived from a metallic foil stack lamination mold, said derived mold defining a protruding undercut and an aspect ratio of greater than 10:1, said derived mold comprising a plurality of surfaces that define a periphery of a layer-less volume of said derived mold, a surface from said plurality of surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a stack lamination mold surface formed by a stacked plurality of metallic foil layers comprised by said stack lamination mold.
A mold derived from a metallic foil stack lamination mold, said derived mold defining a cavity having a protruding undercut and an aspect ratio of greater than 10:1, said derived mold comprising a plurality of surfaces that define a periphery of a layer-less volume of said derived mold, a surface from said plurality of surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a stack lamination mold surface formed by a stacked plurality of metallic foil layers comprised by said stack lamination mold.
A method of forming a casting, comprising:
- filling a mold having a stacked plurality of lithographically-derived micro-machined layers with a first casting material to form a first cast product having an aspect ratio of greater than 10:1, the stacked plurality of lithographically-derived micro-machined layers defining a protruding undercut;
- and
- demolding the first cast product from the mold, such that the mold is not substantially damaged, said first cast product comprising a plurality of component surfaces that define a periphery of a layer-less volume of said first cast product, a component surface from said plurality of component surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by said stacked plurality of layers.
A method of forming a casting, comprising:
- filling a mold having a stacked plurality of lithographically-derived micro-machined layers with a first casting material to form a first cast product having an aspect ratio of greater than 10:1, the stacked plurality of lithographically-derived micro-machined layers defining a protruding undercut;
- and
- demolding the first cast product from the mold such that the mold is not substantially damaged, the first cast product reflecting the protruding undercut, said first cast product comprising a plurality of component surfaces that define a periphery of a layer-less volume of said first cast product, a component surface from said plurality of component surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by said stacked plurality of layers.
Dependencies are inferred from the claim text.