Methods of and apparatus for molding structures using...

Electrolysis: processes – compositions used therein – and methods – Electroforming or composition therefor

Reexamination Certificate

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C205S070000, C264S219000, C264S221000, C264S259000, C264S271100, C264S299000, C264S313000, C264S317000, C264S318000, C264S328100

Reexamination Certificate

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10434315

ABSTRACT:
Molded structures, methods of and apparatus for producing the molded structures are provided. At least a portion of the surface features for the molds are formed from multilayer electrochemically fabricated structures (e.g. fabricated by the EFAB™ formation process), and typically contain features having resolutions within the 1 to 100 μm range. The layered structure is combined with other mold components, as necessary, and a molding material is injected into the mold and hardened. The layered structure is removed (e.g. by etching) along with any other mold components to yield the molded article. In some embodiments portions of the layered structure remain in the molded article and in other embodiments an additional molding material is added after a partial or complete removal of the layered structure.

REFERENCES:
patent: 5190637 (1993-03-01), Guckel
patent: 5234571 (1993-08-01), Noeker
patent: 6027630 (2000-02-01), Cohen
patent: 6422528 (2002-07-01), Domeier et al.
patent: 6660151 (2003-12-01), Lessmollmann et al.
patent: 6692680 (2004-02-01), Lee et al.
Cohen et al., “EFAB: Rapid, low-cost desktop micromachining of high aspect ratio true 3-D MEMS,” 12th IEEE International Conference on Microelectromechanical Systems, pp. 244-251 (Jan. 17-21, 1999).

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