Patent ID: 10539106

Abstract:
A method of fabricating a fuel injector nozzle comprising the steps of: (a) forming a first microstructured pattern in a first material; (b) replicating the first microstructured pattern in a second material to make a first mold comprising a second microstructured pattern in the second material; (c) replicating the second microstructured pattern in a third material to make a second mold comprising a third microstructured pattern comprising a plurality of microstructures in the third material; (d) replicating the third microstructured pattern in a metal material to make a replicated structure; and (e) removing the third material resulting in a nozzle having a plurality of through-holes through the metal material and corresponding to the plurality of microstructures in the third microstructured pattern. Each of the plurality of through-holes has a hole wall connecting a hole entry to a hole exit, and the hole wall of at least one through-hole has a side that curves from its hole entry to its hole exit.