Net-shape structure with micro-truss core

摘要

A curved, three-dimensional, ordered micro-truss structure comprising: a plurality of first struts extending along a first direction; a plurality of second struts extending along a second direction; and a plurality of third struts extending along a third direction, wherein the first, second, and third struts interpenetrate one another at a plurality of nodes, wherein the pluralities of first struts, second struts, third struts, and nodes form a plurality of ordered unit cells within the micro-truss structure, and wherein the plurality of ordered unit cells define a curved surface.

主权项

1. A method of manufacturing a curved, three-dimensional, ordered micro-truss structure, the method comprising:
providing a volume of a photo-monomer; providing a mask between at least one collimated light source and the volume of the photo-monomer, the mask having a plurality of apertures; directing a collimated light beam from the at least one collimated light source to the mask for a period of exposure time, a portion of the collimated light beam passing through the apertures of the mask and into the photo-monomer to form a plurality of polymer waveguides through a portion of the volume of the photo-monomer; removing any uncured photo-monomer to leave behind a partially cured, three-dimensional, ordered micro-truss structure comprising a plurality of ordered unit cells, the partially cured, three-dimensional, ordered micro-truss structure defining an open volume; attaching a first faceplate to a first side of the plurality of ordered unit cells; attaching a second faceplate to a second side of the plurality of ordered unit cells opposite the first side; elastically deforming the micro-truss structure to form a partially cured, curved surface; post-curing the micro-truss structure to form the curved, three-dimensional, ordered micro-truss structure having a cured, curved surface; and applying a metal coating by at least one of electroless plating or electrodeposition to the plurality of ordered unit cells after attaching the first and second faceplates to the first and second sides of the plurality of ordered unit cells, the applying the metal coating comprising supplying a plating solution from a reservoir separated from the micro-truss structure into the micro-truss structure by flowing the plating solution through a first channel having a first end connected to the reservoir and a second end directly connected to a first opening defined in the first faceplate and concurrently flowing the plating solution out of the micro-truss structure through a second channel having a first end connected to the reservoir and a second end directly connected to a second opening defined in the first faceplate, wherein the supplying the plating solution comprises pumping the plating solution through the micro-truss structure with a pump.