Methods for manufacturing three-dimensional devices and devices created thereby
View Patent ↗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.
1. 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.
2. The system of claim 1 , further comprising:
a channel extending through a predetermined set of cast walls of said first consumable ceramic non-planar mold.
3. The system of claim 1 , further comprising:
a plurality of channels extending within said first consumable ceramic non-planar mold.
4. The system of claim 1 , further comprising:
an interconnected plurality of channels extending within said first consumable ceramic non-planar mold.
5. The system of claim 1 , further comprising:
a plurality of protrusions defined by said first consumable ceramic non-planar mold.
6. The system of claim 1 , further comprising:
a sub-cavity defined by said first consumable ceramic non-planar mold.
7. The system of claim 1 , wherein:
said first consumable ceramic non-planar mold is comprised of silica, alumina, and/or zirconium oxide.
8. The system of claim 1 , wherein:
at least one wall surface from said plurality of wall surfaces is non-planar.
9. The system of claim 1 , wherein:
at least one wall surface from said plurality of wall surfaces is anisotropic.
10. The system of claim 1 , wherein:
at least one wall surface from said plurality of wall surfaces is isotropic.
11. The system of claim 1 , wherein:
at least one wall surface from said plurality of wall surfaces has a predetermined surface finish.
12. The system of claim 1 , wherein:
at least one space from said plurality of spaces has a substantially triangular cross-section.
13. The system of claim 1 , wherein:
at least one space from said plurality of spaces has a substantially rectangular cross-section.
14. The system of claim 1 , wherein:
at least one space from said plurality of spaces has a substantially square cross-section.
15. The system of claim 1 , wherein:
at least one space from said plurality of spaces has a substantially hexagonal cross-section.
16. The system of claim 1 , wherein:
at least one space from said plurality of spaces has a substantially circular cross-section.
17. A system comprising:
a first consumable ceramic non-planar mold insert comprising a plurality of interconnected channel molds, each channel mold from said plurality of channel molds at least partially defined by a corresponding 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 insert;
wherein:
said cavity is substantially filled by said first consumable ceramic non-planar mold insert;
said cavity defines a single molding opening for said first consumable ceramic non-planar mold insert;
said demolding opening defines a demolding direction in which said first consumable ceramic non-planar mold insert is removable via said demolding opening from said cavity of said parent mold with damage to neither said first consumable ceramic non-planar mold insert 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.
18. The system of claim 17 , wherein:
said first consumable ceramic non-planar mold insert comprises silica.
19. The system of claim 17 , wherein:
said first consumable ceramic non-planar mold insert comprises alumina.
20. The system of claim 17 , wherein:
said first consumable ceramic non-planar mold insert comprises zirconium oxide.
21. The system of claim 17 , wherein:
at least one wall surface from said plurality of wall surfaces is non-planar.
22. The system of claim 17 , wherein:
at least one wall surface from said plurality of wall surfaces is anisotropic.
23. The system of claim 17 , wherein:
at least one wall surface from said plurality of wall surfaces is isotropic.
24. The system of claim 17 , wherein:
at least one wall surface from said plurality of wall surfaces has a predetermined surface finish.
25. A system comprising:
a first consumable ceramic non-planar mold insert defined by at least one 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 mod insert;
wherein:
said cavity is substantially filled by said first consumable ceramic non-planar mold insert;
said cavity defines a single molding opening or said first consumable ceramic non-planar mold insert;
said demolding opening defines a demolding direction in which said first consumable ceramic non-planar mold insert is removable via said demolding opening from said cavity of said parent mold with damage to neither said first consumable ceramic non-planar mold insert nor said intermediate 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.
26. The system claim 25 , wherein:
said first consumable ceramic non-planar mold insert is comprised of silica, alumina, and/or zirconium oxide.
27. The system claim 25 , wherein:
at least one of said plurality of wall surfaces is non-planar.
28. The system of claim 25 , wherein:
at least one of said plurality of wall surfaces is anisotropic.
29. The system of claim 25 , wherein:
at least one wall surface from said plurality of wall surfaces is isotropic.
30. The system of claim 25 , wherein:
at least one wall surface from said plurality of wall surfaces has a predetermined surface finish.