Batch Methods of Forming Microscale or Millimeter Scale Structures Using Electro Discharge Machining Alone or In Combination with Other Fabrication Methods

摘要

Embodiments are directed to forming three-dimensional millimeter scale or micro-scale structures from single or multiple sheets or layers of material via electro discharge machining (EDM). In some embodiments, the electrodes are formed by single layer or multi-layer, single material or multi-material deposition processes. In some embodiments single electrodes form a plurality of parts or structures simultaneously. In some embodiments a sacrificial bridging material is used to hold parts together during and after EDM processing.

主权项

1. A method for the batch formation of a plurality of micro-scale or millimeter-scale parts, comprising:
a) obtaining at least one EDM electrode representing a layout of the parts to be formed; b) providing a sheet of structural material having a front side and a backside; c) locating a bridging sacrificial material on to the backside of the sheet of structural material; d) preparing the sheet of structural material and the bridging sacrificial material for EDM processing; e) using the at least one EDM electrode to erode or cut selected portions of the sheet so that structural material remains having a configuration of the plurality of parts and such that the plurality of parts remain in place with respect to one another due at least to the presence of the bridging sacrificial material; and f) removing the bridging sacrificial material.