Journal Article10.1007/S00170-014-6746-Y
Laminated fabrication of micro-stepped gear mold based on WEDM and thermal diffusion welding
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TL;DR: In this article, the authors presented a method of micro-double-staged laminated object manufacturing (micro-DLOM) for fabricating three-dimensional (3D) micro-molds and verifies its feasibility of fabricating micro-stepped gear molds.
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Abstract: This paper presents a method of micro-double-staged laminated object manufacturing (micro-DLOM) for fabricating three-dimensional (3D) micro-molds and verifies its feasibility of fabricating of micro-stepped gear molds. First, under the action of 10 μs pulse width, 40 μs pulse interval, 0.28 A wire-cutting current, and 60 V discharge voltage, a 100-μm-thick Cu foil is cut by wire electrical discharge machining (WEDM) to obtain a multilayer two-dimensional (2D) microstructure. Under the technological parameters of 850 °C thermal diffusion temperature, 10 h thermal diffusion time, and 1.0 N/mm2 pressure, the multilayer Cu 2D microstructure is then connected by vacuum-pressure thermal diffusion welding to fit the gear molds with two- and three-stage steps. Finally, on the basis of ultrasonic powder molding, two- and three-stage step plastic gears are respectively obtained. Compared with the ultraviolet lithography (UV-LIGA) process, the new process can fabricate complicated 3D microstructure with free-form surfaces; compared with the femtosecond laser-layering flat-scanning ablation process, the new process cuts only 2D microstructure of each layer with high processing efficiency; and compared with the micro-electrical discharge machining (EDM) process, the new process omits the step of microelectrode fabrication. Moreover, because there is no loss in the course of the microelectrode process, micro-molds in which the depth-to-width ratio is beyond limitation can be fabricated.
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Citations
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References
Fabrication of 3D metal micro-mold based on femtosecond laser cutting and micro-electric resistance slip welding
TL;DR: In this paper, a femtosecond laser cutting and micro-electric resistance slip welding was used to address the bottleneck presented by ultraviolet-Lithographie, Galvanoformung, Abformung combined with micro-electroforming, in which micro-molds are usually fabricated with vertical wall structures.
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Fabrication of metallic micromolds by laser and electro-discharge micromachining
TL;DR: In this paper, a method of creating metallic micromolds with features that have high-aspect ratios is described, which utilizes laser micromachining to cut the negative two-dimensional profiles of the desired microfeatures and fluidic network patterns on a 100μm thick brass sheet.
A batch-mode micromachining process for spherical structures
TL;DR: In this article, a self-aligned three-dimensional process (3D-SOULE) that incorporates batchmode micro ultrasonic machining, lapping and micro electro-discharge machining (µEDM) for fabrication of concave and mushroom-shaped spherical structures from hard and brittle materials is presented.
Microstructuring of Steel and Hard Metal using Femtosecond Laser Pulses
TL;DR: In this article, a high-precision fs-laser micromachining station was used for 3D micro-structuring of tungsten carbide hard metal and steel using femtosecond laser pulses.
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Microceramic injection molding of a multilayer micropatterned micropart
TL;DR: In this paper, a multilayer micropart with zirconia (ZrO2) feedstock was developed and applied to develop a multi-exposure multi-development UV-Lithographie, Galvanoformung, Abformung (LIGA), µCIM, variothermal temperature control, and Taguchi experimental method are integrated and applied.
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