US 9,208,916 B2Granted

Methods for manufacturing three-dimensional devices and devices created thereby

AssigneeMikro Systems, Inc.

InventorsMichael P. Appleby, Iain Fraser, James E. Atkinson

Life of this patent

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Abstract

In certain exemplary embodiments of the present invention, three-dimensional micro-mechanical devices and/or micro-structures can be made using a production casting process. As part of this process, an intermediate mold can be made from or derived from a precision stack lamination and used to fabricate the devices and/or structures. Further, the micro-devices and/or micro-structures can be fabricated on planar or nonplanar surfaces through use of a series of production casting processes and intermediate molds. The use of precision stack lamination can allow the fabrication of high aspect ratio structures. Moreover, via certain molding and/or casting materials, molds having cavities with protruding undercuts also can be fabricated.

Claims30

Dependent claims

A system comprising:

a first consumable ceramic non-planar mold defining a plurality of spaces, each space from said plurality of spaces at least partially bounded by a cast wall comprising a plurality of wall surfaces;
and
a parent mold that defines a cavity configured to mold said first consumable ceramic non-planar mold;
wherein:
said cavity is substantially filled by said first consumable ceramic non-planar mold;
said cavity define a single demolding opening for said first consumable ceramic non-planar mold;
said demolding opening defines a demolding direction in which said first consumable ceramic non-planar mold is removable via said demolding opening from said cavity of said parent mold with damage to neither said first consumable ceramic non-planar mold nor said parent mold;
said cavity defines a first cavity cross-sectional area that extends solely within a first cavity plane that is oriented perpendicularly to said demolding direction;
said cavity defines a second cavity cross-sectional area that extends solely within a second cavity plane that is oriented perpendicularly to said demolding direction;
said first cavity cross-sectional area is smaller than said second cavity cross-sectional area;
and
said first cavity plane is closer to said demolding opening than said second cavity plane.

9 more elements

Dependencies are inferred from the claim text.

Facts

Application: 12/141,455Filed 18 Jun 2008 · continuation
Priority: 5 Jun 2001
Published: US 2008/0246180 A19 Oct 2008
Granted: 8 Dec 2015
Term ends: Not estimatedThe source records don’t support an estimate.

Classification37 codes

B23P 15/246
Dies: laminated dies
A61B 6/502
Specially adapted for specific body parts; specially adapted for specific clinical applications: for diagnosis of breast, i.e. mammography
B22D 19/00
Casting in, on, or around objects which form part of the product
B22D 29/00
Removing castings from moulds, not restricted to casting processes covered by a

Family

Application60/295,564Us provisional application · filed 5 Jun 2001
Application60/339,773Us provisional application · filed 17 Dec 2001
PCT/US02/17936Parent of this continuation · filed 5 Jun 2002
US 2008/0246180 A1Pre-grant publication · published 9 Oct 2008
Application10/479,335Parent of this continuation
US 7,410,606 B2Parent of this continuation
US 2004/0156478 A1Published application
US 9,208,916 B2This patent

From the US filing history. Foreign family members aren’t listed.