Digital 3D Fabrication Using Multi-Layered Mold

摘要

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.

主权项

1. A method for fabricating a three dimensional (3D) structure, the method comprising:
sequentially depositing a plurality of mold material layers such that the plurality of mold material layers collectively form a multi-layer mold; individually patterning each of the plurality of mold material layers in accordance with a digital description such that each said mold material layer defines a void portion; and depositing a modeling material portion into each said void portion such that each said modeling material portion fills an associated void portion before depositing a subsequent mold material layer of said plurality of mold material layers, and such that said modeling material portions disposed in said plurality of mold material layers collectively form said 3D structure.