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Title: Castable plastic mold with electroplatable base

Abstract

A sacrificial plastic mold having an electroplatable backing is provided as are methods of making such a mold via the infusion of a castable liquid formulation through a porous metal substrate (sheet, screen, mesh or foam) and into the features of a micro-scale master mold. Upon casting and demolding, the porous metal substrate is embedded within the cast formulation and projects a plastic structure with features determined by the mold tool. The plastic structure provides a sacrificial plastic mold mechanically bonded to the porous metal substrate, which provides a conducting support suitable for electroplating either contiguous or non-contiguous metal replicates. After electroplating and lapping, the sacrificial plastic can be dissolved, leaving the desired metal structure bonded to the porous metal substrate. Optionally, the electroplated structures may be debonded from the porous substrate by selective dissolution of the porous substrate or a coating thereon.

Inventors:
; ; ;
Issue Date:
Research Org.:
Sandia National Lab. (SNL-CA), Livermore, CA (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1174691
Patent Number(s):
6,679,471
Application Number:
10/052,948
Assignee:
Sandia National Laboratories (Livermore, CA) SNL-L
DOE Contract Number:  
AC04-94AL85000
Resource Type:
Patent
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; 42 ENGINEERING

Citation Formats

Domeier, Linda A., Morales, Alfredo M., Gonzales, Marcela G., and Keifer, Patrick M. Castable plastic mold with electroplatable base. United States: N. p., 2004. Web.
Domeier, Linda A., Morales, Alfredo M., Gonzales, Marcela G., & Keifer, Patrick M. Castable plastic mold with electroplatable base. United States.
Domeier, Linda A., Morales, Alfredo M., Gonzales, Marcela G., and Keifer, Patrick M. Tue . "Castable plastic mold with electroplatable base". United States. https://www.osti.gov/servlets/purl/1174691.
@article{osti_1174691,
title = {Castable plastic mold with electroplatable base},
author = {Domeier, Linda A. and Morales, Alfredo M. and Gonzales, Marcela G. and Keifer, Patrick M.},
abstractNote = {A sacrificial plastic mold having an electroplatable backing is provided as are methods of making such a mold via the infusion of a castable liquid formulation through a porous metal substrate (sheet, screen, mesh or foam) and into the features of a micro-scale master mold. Upon casting and demolding, the porous metal substrate is embedded within the cast formulation and projects a plastic structure with features determined by the mold tool. The plastic structure provides a sacrificial plastic mold mechanically bonded to the porous metal substrate, which provides a conducting support suitable for electroplating either contiguous or non-contiguous metal replicates. After electroplating and lapping, the sacrificial plastic can be dissolved, leaving the desired metal structure bonded to the porous metal substrate. Optionally, the electroplated structures may be debonded from the porous substrate by selective dissolution of the porous substrate or a coating thereon.},
doi = {},
journal = {},
number = ,
volume = ,
place = {United States},
year = {2004},
month = {1}
}

Patent:

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