Patent ID: 6841306

Claim:
A method for preparing a polymeric mold for producing a micro-scale part comprising the steps of: a) introducing a substrate having a photoresist layer into a developer solution, a portion of said layer having been exposed to a source of radiation, said developer solution for dissolving said exposed portion; b) applying a source of high frequency sonic agitation to said solution and to said layer for a period of minutes, said high frequency sonic agitation for assisting in removing said dissolving exposed portion; c) removing said substrate and said layer from said developer solution and immediately introducing said substrate and said layer into an intermediate rinse solution, consisting essentially of an aqueous solution of di(ethylene glycol) butyl either, said intermediate rinse solution for assisting in further removing and for preventing recrystallization of portions of said exposed photoresist left undissolved by said developer solution; d) applying a source of high frequency sonic agitation to said intermediate rinse solution and to said layer for a period of minutes; and e) removing said substrate and said layer from said intermediate solution and immediately introducing said substrate and said layer into a water rinse, said rinse for removing traces of said intermediate rinse solution.