Methods for manufacturing three-dimensional devices and devices created thereby

1. 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.

2. The method of claim 1 , further comprising providing the mold.

3. The method of claim 1 , further comprising, for each of the stacked plurality of lithographically-derived micro-machined layers, designing a feature associated with the layer.

4. The method of claim 1 , further comprising designing a feature associated with all of the stacked plurality of lithographically-derived micro-machined layers of the mold.

5. The method of claim 1 , further comprising micro-machining each of the stacked plurality of lithographically-derived micro-machined layers.

6. The method of claim 1 , further comprising, for each of the stacked plurality of lithographically-derived micro-machined layers, micro-machining a feature associated with the layer.

7. The method of claim 1 , further comprising micro-machining a feature associated with all of the stacked plurality of lithographically-derived micro-machined layers.

8. The method of claim 1 , further comprising stacking the stacked plurality of lithographically-derived micro-machined layers.

9. The method of claim 1 , further comprising aligning the stacked plurality of lithographically-derived micro-machined layers.

10. The method of claim 1 , further comprising bonding the stacked plurality of lithographically-derived micro-machined layers.

11. The method of claim 1 , further comprising clamping the stacked plurality of lithographically-derived micro-machined layers.

12. The method of claim 1 , further comprising securing the stacked plurality of lithographically-derived micro-machined layers.

13. The method of claim 1 , further comprising affixing the stacked plurality of lithographically-derived micro-machined layers.

14. The method of claim 1 , further comprising fabricating the mold.

15. The method of claim 1 , further comprising allowing the first casting material to solidify to form the first cast product.

16. The method of claim 1 , further comprising surrounding the first cast product with a second casting material.

17. The method of claim 1 , further comprising surrounding the first cast product with a second casting material and allowing the second casting material to solidify into a second cast product.

18. The method of claim 1 , further comprising surrounding the first cast product with a second casting material and allowing the second casting material to solidify into a nonplanar second cast product.

19. The method of claim 1 , further comprising forming the first cast product into a non-planar shape.

20. The method of claim 1 , further comprising forming the first cast product into a non-planar shape and surrounding the formed first cast product with a second casting material and allowing the second casting material to solidify into a nonplanar second cast product.

21. The method of claim 1 , further comprising surrounding the first cast product with a second casting material and demolding a second cast product formed from the second casting material.

22. The method of claim 1 , wherein the first casting material comprises a flexible polymer.

23. The method of claim 1 , wherein the first casting material comprises an elastomer.

24. The method of claim 1 , wherein the first casting material comprises silicone rubber.

25. The method of claim 1 , wherein the stacked plurality of lithographically-derived micro-machined layers define a cavity having a protruding undercut.

26. The method of claim 1 , wherein the stacked plurality of lithographically-derived micro-machined layers define a plurality of cavities therein.

27. The method of claim 1 , further comprising positioning an insert into a cavity defined by the stacked plurality of lithographically-derived micro-machined layers.

28. The method of claim 1 , further comprising positioning an insert into a cavity defined by the stacked plurality of lithographically-derived micro-machined layers, the insert occupying only a portion of the cavity.

29. The method of claim 1 , further comprising positioning an insert into a cavity defined by the stacked plurality of lithographically-derived micro-machined layers prior to said filling the mold with the first casting material.

30. The method of claim 1 , further comprising positioning a lithographically-derived micro-machined insert into a cavity defined by the stacked plurality of lithographically-derived micro-machined layers prior to said filling the mold with the first casting material.

31. The method of claim 1 , wherein the first cast product has an aspect ratio greater than 100:1.

32. The method of claim 1 , further comprising surrounding the first cast product with a second casting material and demolding a second cast product formed from the second casting material, the second cast product having an aspect ratio greater than 100:1.

33. The method of claim 1 , wherein a cavity defined by the stacked plurality of lithographically-derived micro-machined layers has an aspect ratio greater than 100:1.

34. The method of claim 1 , wherein the first cast product is an end product.

35. The method of claim 1 , further comprising surrounding the first cast product with a second casting material and demolding a second cast product formed from the second casting material, the second cast product being an end product.

36. The method of claim 1 , wherein the first cast product is attached to a substrate.

37. The method of claim 1 , wherein the first cast product is a free-standing structure.

38. 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.

39. 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.

40. 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.

41. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40 , wherein said mold is a positive replication of a predetermined end product.

42. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40 , wherein said mold is a negative replication of a predetermined end product.

43. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40 , wherein said mold defines at least one feature having an aspect ratio of greater than 10:1.

44. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40 , wherein said mold defines at least one feature having an aspect ratio of greater than 15:1.

45. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40 , wherein said mold defines at least one feature having an aspect ratio of greater than 20:1.

46. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40 , wherein said mold defines at least one feature having an aspect ratio of greater than 25:1.

47. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40 , wherein said mold defines at least one feature having an aspect ratio of greater than 30:1.

48. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40 , wherein said mold defines at least one feature having an aspect ratio of greater than 40:1.

49. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40 , wherein said mold defines at least one feature having an aspect ratio of greater than 50:1.

50. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40 , wherein said mold defines at least one feature having an aspect ratio of greater than 75:1.

51. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40 , wherein said mold defines at least one feature having an aspect ratio of greater than 100:1.

52. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40 , wherein said mold defines at least one feature having an aspect ratio of greater than 150:1.

53. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40 , wherein said mold defines at least one feature having an aspect ratio of greater than 200:1.

54. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40 , wherein said mold defines at least one feature having an aspect ratio of greater than 250:1.

55. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40 , wherein said mold defines at least one feature having an aspect ratio of greater than 300:1.

56. The lithographically-derived micro-machined metallic foil stack lamination mold of claim 40 , wherein said mold defines at least one feature having an aspect ratio of greater than 400:1.

57. A metallic foil stack lamination mold that defines a protruding undercut and an aspect ratio of greater than 10:1.

58. A metallic foil stack lamination mold that defines a cavity having a protruding undercut and an aspect ratio of greater than 10:1.

59. 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.

60. 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.

61. 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.

62. 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.

63. 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.