Patent ID: 6692680
Filing Date: 2004-02-17
Classification: B29C,B81C

Abstract:
A method for the mass production of substantially identical microstructures, said method comprising the steps of:(a) fabricating a first micromold insert having a size and shape that are generally complementary to the size and shape of the desired microstructures; (b) fabricating at least one inverse replication of the first micromold insert by depositing a polymeric precursor onto the first micromold insert, and curing the polymeric precursor into a polymeric inverse replication, wherein the accuracy of the polymeric inverse replication is at least about 10 microns; (c) coating the inverse replication with an electrically conductive layer; (d) electroplating a metallic form complementary to the inverse replication, using the electrically conductive layer as a cathode; (e) etching away the electrically conductive layer from the form to produce a second, metallic micromold insert, whose dimensions differ from the dimensions of the first micromold by an amount corresponding to the thickness of the electrically conductive layer, (f) repeating steps (c) through (e) a plurality of times to produce a plurality of second micromold inserts; and (g) molding a plurality of substantially identical, polymeric microstructures from the second micromold inserts.