No abstract

No abstract

Novel technology is presented which allows the rapid replication of electroforming plastic micromolds. This technique incorporates microscreens into hot embossing or injection molding processes to produce sacri®cial molds with conducting bases and insulating sidewalls. Both contiguous and non-contiguous features can be electroformed from these molds. Process parameters including the microscreen geometry and the use of multiple porous metal inserts are discussed.

Corresponding author: amorale@sandia.gov; phone 925 294 3540; fax 925 294 3410; ABSTRACT A novel process for the rapid replication of electroforming plastic micromolds has been developed and is now being used to produce plated nickel test specimens. The process combines hot embossing or injection molding with metallic microscreens to produce sacrificial electroforming molds with conducting bases and insulating sidewalls. The replicated micromolds differ from standard LIGA molds in that the holes in the microscreen act as insulating defects in the electroforming base. The effects of such defects on the materials properties of electroformed microparts will be discussed and it will be shown that when the surface irregularities corresponding to the microscreen holes are removed, mechanical properties are experimentally indistinguishable from those found in conventionally processed LIGA specimens.