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    • 5. 发明授权
    • Digital 3D fabrication using multi-layered mold
    • 数字3D制作采用多层模具
    • US09156194B2
    • 2015-10-13
    • US13831358
    • 2013-03-14
    • Palo Alto Research Center Incorporated
    • Tse Nga NgJengPing LuEugene M. ChowTimothy David StoweJanos VeresPhilipp H. Schmaelzle
    • B29C33/38B29C67/00B29C33/44B29C33/00
    • B29C33/3835B29C33/005B29C33/3842B29C33/448B29C64/00B29C64/106B29C67/0051B29C67/0055B29C2033/385
    • A replica 3D structure is fabricated inside a multi-layered mold by patterning each mold layer to define a void/opening that matches a corresponding cross section of the structure's peripheral surface, and filling the patterned opening of each layer with a structural material (i.e., before depositing a subsequent layer of mold material). The mold material (e.g., photoresist or another dissolvable sacrificial material) is blanket deposited (e.g., by slot-die, spray coating) and then patterned using a laser or a printed mask. Each layer of modeling material (e.g., polymer, ceramic or metal, or a combination thereof) is electro-plated or otherwise deposited on the previously formed modeling material layer. High vertical resolution is achieved by utilizing relatively thin mold layers. The mold layer deposition, patterning and modeling material deposition is repeated until the replica 3D structure is entirely formed inside the multi-layered mold, and then the mold is dissolved or otherwise removed.
    • 复制3D结构通过图案化每个模具层以形成与结构的周边表面的相应横截面相匹配的空隙/开口,并且用结构材料填充每个层的图案化开口(即, 在沉积后续的模具材料层之前)。 模具材料(例如,光致抗蚀剂或另一种可溶解的牺牲材料)被覆盖沉积(例如,通过狭缝模头,喷涂),然后使用激光或印刷掩模进行图案化。 每层建模材料(例如,聚合物,陶瓷或金属或其组合)被电镀或以其他方式沉积在先前形成的建模材料层上。 通过使用相对薄的模具层实现高垂直分辨率。 重复模层沉积,图案化和建模材料沉积,直到复制3D结构完全形成在多层模具内,然后模具被溶解或以其他方式去除。