Abstract: A tool for embossing high aspect ratio microstructures is provided, wherein the microstructures provide decreased surface reflection and increased transmission through an optical component even at high incident angles. The tool is fabricated by a process that comprises anisotropic etching of columnar pits in a silicon substrate using inductively coupled plasma, followed by isotropic reactive ion etching of the columnar pits to create relatively pointed obelisks. The silicon substrate is then preferably rinsed to remove remaining photoresist prior to vapor depositing a conductive layer thereon. Finally, a metal is electroformed over the conductive layer to form the embossing tool. The embossing tool is then pressed against an optical coating, for example a polymer sheet, to create microstructures having aspect ratios from 1 to 5.

Abstract: A method of manufacturing a stamper/imprinter for use in patterning of a recording medium, comprising sequential steps of: (a) providing a permanent master comprising a body of a substantially rigid material having a surface with a topographical pattern formed therein comprising a patterned plurality of spaced-apart recesses with a plurality of non-recessed areas therebetween, the topographical pattern corresponding to a pattern to be formed in a recording medium; (b) forming a layer of a substantially rigid material over the surface of the permanent master with the topographical pattern formed therein; (c) separating the layer of a substantially rigid material from the master, the layer of a substantially rigid material having an imprinting surface with a topographical pattern formed therein replicating the topographical pattern of the permanent master; and (d) repeating steps (b) and (c) multiple times with the permanent master provided in step (a) to form a plurality of stampers/imprinters.

Abstract: A method of manufacturing a metal microstructure by using a resin mold.

Abstract: A compliant cantilevered three-dimensional micromold is provided. The compliant cantilevered micromold is suitable for use in the replication of cantilevered microparts and greatly simplifies the replication of such cantilevered parts. The compliant cantilevered micromold may be used to fabricate microparts using casting or electroforming techniques. When the compliant micromold is used to fabricate electroformed cantilevered parts, the micromold will also comprise an electrically conducting base formed by a porous metal substrate that is embedded within the compliant cantilevered micromold. Methods for fabricating the compliant cantilevered micromold as well as methods of replicating cantilevered microparts using the compliant cantilevered micromold are also provided.

Abstract: A method of producing an optical element forming die, includes the steps of: cutting a base member to form a base optical surface of the base member while rotating the base member; cutting an outer circumferential surface of the base member so that an optical axis of the base optical surface is identical to a rotation center of the outer circumferential surface of the base member while rotating the base member; forming an optical surface having a predetermined pattern onto the base optical surface of the base member; forming an electroforming mold having an optical transfer surface complementary to the optical surface of the base member by electroforming wherein the electroforming is conducted with the base member; and cutting an outer circumferential surface of the electroforming mold on the basis of the outer circumferential surface of the base member.

Abstract: A process for producing microstructured tool insert for injection molding a part, the part being fabricated of a synthetic material, a metal or a ceramic material and including an arrangement of microstructures which are formed on an outer surface of the part and have two different predetermined depths.

Abstract: The method includes the step of forming a solid epoxy member on a substrate, the epoxy member having an upper surface of desired configuration. A first metal layer is deposited on the epoxy member with the upper surface thereof conforming to the desired configuration. A layer of epoxy is deposited on the first metal layer and epoxy material from the epoxy layer is removed to create a well, exposing the metal layer on the epoxy member. A metal impression layer is then deposited in the well. The metal impression layer is then removed from the well and affixed to a mounting member as a mold component for injection molding of small structures.

Abstract: A method of producing a die for forming an optical element including; a positioning step to fix temporarily under the state wherein a plurality of members at least one of which has a die transfer surface are positioned with their connection surfaces being put to face each other, and an electroforming connection step to connect both members by forming an electroforming mold on a circumference of the connection surface under the state where the plural members are positioned.

Abstract: A method for manufacturing a metal mask that facilitates easy dimensional control in the manufacturing process and can manufacture multiple metal masks having high and consistent precision. A Cr film 2 having a mask pattern 2a is formed on the surface of a glass plate 1, a dry film 4 is formed on the Cr film 2, the dry film 4 is exposed from the glass plate 1 side with the Cr film 2 as a mask, a mask pattern 4a having the same shape as that of the mask pattern 2a is formed on the dry film 4, and a metal plating layer 6 is formed on the Cr film 2. The metal plating layer 6 is separated to form a metal mask 7.

Abstract: A sacrificial plastic mold having an electroplatable backing is provided. One embodiment consists of the infusion of a softened or molten thermoplastic through a porous metal substrate (sheet, screen, mesh or foam) and into the features of a micro-scale molding tool contacting the porous metal substrate. Upon demolding, the porous metal substrate will be embedded within the thermoplastic and will project a plastic structure with features determined by the mold tool. This plastic structure, in turn, provides a sacrificial plastic mold mechanically bonded to the porous metal substrate which provides a conducting support suitable for electroplating either contiguous or non-contiguous metal replicates. After electroplating and lapping, the sacrificial plastic can be dissolved to leave the desired metal structure bonded to the porous metal substrate. Optionally, the electroplated structures may be debonded from the porous substrate by selective dissolution of the porous substrate or a coating thereon.

Abstract: The invention discloses a microelectroforming mold using a preformed metal as the substrate and its fabrication method. Using a preformed metal as the substrate can avoid deformation of the microelectroforming mold due to residual stress in the electroforming metal. The fabrication method disclosed herein includes the steps of: forming a layer of bonding material on a surface of the preformed metal substrate after machining; forming a high aspect ratio photoresist microstructure on surfaces of the metal substrate and the bonding material; putting an electroforming material into the gaps of the photoresist microstructure to form an electroforming metal microstructure; and using a thermal process to bond the metal substrate and the metal micro structure by the bonding material and simultaneously bum off the photoresist microstructure to form a micro-electroforming mold.

Abstract: The present invention describes a method for rapidly fabricating a robust 3-dimensional silicon micro-mold for use in preparing complex metal micro-components. The process begins by depositing a conductive metal layer onto one surface of a silicon wafer. A thin photoresist and a standard lithographic mask are then used to transfer a trace image pattern onto the opposite surface of the wafer by exposing and developing the resist. The exposed portion of the silicon substrate is anisotropically etched through the wafer thickness down to conductive metal layer to provide an etched pattern consisting of a series of rectilinear channels and recesses in the silicon which serve as the silicon micro-mold. Microcomponents are prepared with this mold by first filling the mold channels and recesses with a metal deposit, typically by electroplating, and then removing the silicon micro-mold by chemical etching.

Abstract: In the method of manufacturing a ferrule, electrocasting is carried out using at least one wire 9 such as of a metal or a plastic as a mother die, and then the wire 9 is removed from the resulting electrocast product, wherein the electrocasting treatment is carried out under rotation of the wire while it is maintained static in the longitudinal direction. According to this method, neither biased thickening nor bending occurs in the electrocast products, and they are almost free from decentering of holes. Intermediate rod products obtained after the electrocasting treatment have perfectly circular cross sections. In addition, variation in the diameter of the rod products can be reduced. Besides, agitation of the electrocasting solution can be facilitated by employing a method in which agitation is achieved by forced circulation of the liquid, and further deterioration of the electrocasting working environment can be prevented.

Abstract: An optical disk and a method of producing it, particularly a stamper for molding a semiconductor disk base capable of forming an optical disk sufficiently compatible with commercially available CD (Compact Disk) players, a method of producing a stamper, a method of producing an optical disk base, a method of producing an optical disk, and an optical disk base and optical disk are disclosed. The present invention improves both of transferability and tact of an optical disk base molding cycle, allows a fine pattern to be formed in a transfer surface, and makes it needless to change existing molding equipment. In addition, when guide grooves formed in the optical disk are filled with a pigment by spin coating, the guide grooves have a substantially uniform configuration in the radial direction of the disk. The optical disk is sufficiently compatible with various CD players available on the market.

Abstract: A method for annealing a structure formed by electrodeposition including providing the electrodeposition structure, the electrodeposition structure including an eletroformed mold, the electroformed mold having a nominal thickness between and including 0.5 mm to 8.0 mm and having a melting temperature; heating the electrodeposition structure to a temperature between ambient temperature and the melting temperature of the electrodeposition structure; isostatically pressurizing the electrodeposition structure to a pressure above ambient pressure; cooling the electrodeposition structure to ambient temperature; and depressurizing the electrodeposition structure to ambient pressure.

Abstract: This disclosure relates to a method for making a polymeric article mold, a method for making a polymeric article with that mold, and improved surface topography features for a polymeric article. A prototype article is formed and then coated with a thin conductive layer. The coated prototype article is then electroformed until nickel plated to a sufficient depth to define a nickel plating tool. After the prototype article has been removed from the mold face of the nickel tool, the tool can be used as a mold for forming finished polymeric articles which replicate the original prototype article. The use of fine topography features such as a dense upstanding stem array on the surface of the prototype article facilitates accurate and complete electroforming by increased surface area presentation. The disclosure also presents improvements to microreplicated surface structures such as stem arrays.

Abstract: This disclosure relates to a method for making a polymeric article mold, a method for making a polymeric article with that mold, and improved surface topography features for a polymeric article. A prototype article is formed and then coated with a thin conductive layer. The coated prototype article is then electroformed until nickel plated to a sufficient depth to define a nickel plating tool. After the prototype article has been removed from the mold face of the nickel tool, the tool can be used as a mold for forming finished polymeric articles which replicate the original prototype article. The use of fine topography features such as a dense upstanding stem array on the surface of the prototype article facilitates accurate and complete electroforming by increased surface area presentation. The disclosure also presents improvements to microreplicated surface structures such as stem arrays.

Abstract: A method for producing a self-supporting electron-optical transparent structure that includes multi-layer strips and recesses located between the multi-layer strips. The method includes applying a first layer to a second layer, presetting a pattern by exposing or irradiating the first layer and etching the pattern out of the first layer so that partial areas of the second layer are uncovered. The method further includes galvanically applying layers to the uncovered partial areas of the second layer so that multi-layer strips are formed thereon and an electron-optical transparent structure is formed and removing the electron-optical transparent structure off the second layer.

Abstract: A method of fabricating a PVC ornamental article having effects of imitated materials includes steps of: (a) mold casting: making a prototype of a desired ornamental article, exploding said prototype into a plurality of blank elements, coating said blank elements with silicone to form hollow silicone molds, injecting a wax material into said hollow silicone molds to obtain a wax object, taking out said wax object for trimming and electroplating said wax object, and melting said wax object to obtain a mold; (b) blank formation: adding colorants into said PVC plastic material and mixing said colorants to obtain desired colors, injecting said PVC plastic material into said mold, utilizing centrifugal force to affix said PVC plastic material onto an inner wall of said mold, and removing molded PVC from said mold to form a blank by force before said molded PVC dries, filling a filler into said blank to increase hardness; and (c) assembly: assembling blanks together and joining the blanks with other decorations to

Abstract: There is described a method for depicting a predetermined diffraction structure on a substrate by scanning an electron beam onto the substrate. The method includes the steps of: measuring a contour of the substrate so as to detect height errors in surface heights in comparison with specified values of a surface height distribution of the substrate; adjusting a depicting mode for depicting each of diffraction gratings, which constitute the predetermined diffraction structure, in response to the height errors detected in the measuring step, so as to compensate for a phase change of diffracted light caused by each of the height errors corresponding to each of the diffraction gratings; and depicting each of the diffraction gratings by scanning the electron beam onto the substrate, according to the depicting mode adjusted in the adjusting step. The depicting mode represents each spacing between the diffraction gratings or a dose of the electron beam.

Abstract: A V-groove mold fabrication method is disclosed. The method for fabricating a V-groove mold includes the following steps: (a) providing a matrix substrate having a plurality of V-grooves, and then forming a metal layer on said matrix substrate; immersing said matrix substrate having said metal layer thereon with an electroforming metal ion solution and forming a father mold by an electroforming process; and separating said father mold from said matrix substrate.

Abstract: The method includes the step of forming a solid epoxy member on a substrate, the epoxy member having an upper surface of desired configuration. A first metal layer is deposited on the epoxy member with the upper surface thereof conforming to the desired configuration. A layer of epoxy is deposited on the first metal layer and epoxy material from the epoxy layer is removed to create a well, exposing the metal layer on the epoxy member. A metal impression layer is then deposited in the well. The metal impression layer is then removed from the well and affixed to a mounting member as a mold component for injection molding of small structures.

Abstract: A method for treating a film by providing a structure including a substrate and an array of upstanding projections each of which includes multiple contact points. The structure is pressed against the surface of a polymeric film to cause deformation or rupture of the film. The film may then be pressed to partially reseal the perforations. The structure can be produced by electroplating a mould which includes an array of elements of dimensions corresponding to the projections of the desired structure.

Abstract: An insert for a mold, particularly a thermoplastic injection mold, including a stamper having an impression surface and a backing surface. The insert also has a support block having a facing surface having a plurality of projections thereon, with the plurality of projections in contact with the backing surface. A quantity of adhesive is disposed between the sides of the projections adhering the facing surface to the backing surface. A method for fabricating such an insert for a mold is also disclosed.

Abstract: The invention comprises a printing cylinder precursor comprising a plastics cylinder in which is located an immovable spine. The invention further extends to a moulding apparatus for manufacturing a printing cylinder precursor, comprising a cylindrical moulding vessel comprising an inlet for the ingress of moulding material, the vessel further comprising a removable spine located centrally within the moulding vessel. The invention further extends to methods of manufacturing printing cylinder precursors and gravure printing cylinders.

Abstract: A mold used to form a magnetic member includes a mold body having a mold opening, a mold support that supports the mold cavity, and a mold insert. The mold insert is disposed in the mold opening of the mold body to form a mold cavity. The mold insert is coated with a coating to protect the mold body from chemical attack and abrasive wear of the mold material. The coating comprises an electroless nickel layer formed on or over the mold insert, and a chromium nitride layer formed on or over the electroless nickel layer. The mold insert can be formed of beryllium-copper (Be—Cu).

Abstract: A method for fabricating a mold for a microlens having a desired radius (R) of curvature by electroplating. In this method, a minimum radius (Rmin) of curvature is utilized to achieve the desired curvature radius.

Abstract: Process for producing a tool insert for injection molding a part which is produced from a synthetic material, a metal or a ceramic material and which comprises an arrangement of microstructures which are formed on an outer surface of the part and have a predetermined depth.

Abstract: The invention relates to yarns, fibres or filaments that can be fibrillated and to a method and device for their production. According to the invention, said yarns, fibres or filaments consist of at least two elementary filaments of a polymer A and each second elementary filament is sheathed with the polymer B.

Abstract: In order to produce precision optic elements using injection molded plastic, a metal mold is fabricated from two positive masters comprising exact metallic reproductions of the desired plastic part and on which a metal shell has been electroformed or otherwise plated. Two positive masters are required for each mold, one being formed to define the upper part of the mold and the other the lower part of the mold. Each positive master is scribed with an axial line and with a cutting line slightly offset from the axial line, the cutting line for the upper part of the mold being below the axial line and the cutting line for the lower part of the mold being above the axial cutting line. The positive masters are then cut along their cutting lines, the metal shells removed, and the portion of the remaining metal shells between their axial lines and their cutting lines is then trimmed. The upper and lower parts of the mold are then combined to define the complete injection mold.

Abstract: A production method of a light guide and a stamper, combining anisotropic etching and isotropic etching. First a plurality of microstructures is formed on a back surface and a front surface of the substrate. By electroforming, rear and front stampers are made from the back and front surfaces of the substrate. Light guides are produced using the rear and front stampers. Anisotropic etching is performed on the front surface of the substrate, forming V-shaped, U-shaped or pyramid like microstructures. Isotropic etching is performed on the back surface of the substrate, forming quadratic, bowl like, oval or semicircular microstructures. If a transparent substrate is used, then after finishing the etching of microstructures, a light source, a reflector, a diffusion sheet and a prism sheet are added, simulating a back light module for performing a test of luminosity, uniformity of light intensity and light emission angle, so that optical properties are known before proceeding with inverse-forming of the stampers.

Abstract: The present invention is to provide a production method for an optical disc, capable of obtaining a good S/N ratio without deterioration of the stamper quality due to reaction with an electron attractive group contained in a resist material. The processes of forming a resist film on a substrate, patterning the resist film on the substrate by an electron beam cutting, forming a nickel alloy thin film on the patterned resist film, forming a nickel layer on the nickel alloy thin film by the electrocasting, and injection molding of a resin, using the nickel layer peeled off from the nickel alloy thin film as a stamper, are provided. The nickel alloy thin film has a composition containing Ni element as the main component as well as Ru element by less than 25% by weight.

Abstract: Methods of rapidly prototyping microstructures such as HARMs are disclosed. A high precision process uses polymeric microstructure replication techniques and sacrificial layer etching techniques to mass produce high aspect ratio metallic and polymer micromold inserts. In one embodiment, after fabrication of an initial micromold insert, high aspect ratio replications are created by casting replication material, such as PDMS, directly onto the initial micromold insert. The replicated HARM is coated with a sacrificial layer and then electroplated to replicate another set of micromold inserts. After the electroplating process is completed, the sacrificial layer is etched away to release the replicated micromold inserts.

Abstract: A sacrificial core (304) defining a cavity in a metallic or non-metallic shaped article of manufacture, e.g., a casting (302), is made from a metal that can be electrolytically dissolved. The sacrificial core (304) is removed from the article (302) by electrochemical machining. The sacrificial core (304) may be a hollow shell (306) incorporating an integral electrode (308) within the shell and electrically insulated from the shell.

Abstract: A method for impressing holographic images or holograms in the surface of sporting and fitness products such as ball bats and bicycle frames. The surfaces of metal shims and print rolls bearing holograms are hardened as by coating them with thin amorphous diamond coatings or diamond like coatings so the holograms can be embossed into many thousands of metal objects with clarity and consistency.

Abstract: Molded structures, methods of and apparatus for producing the molded structures are provided. At least a portion of the surface features for the molds are formed from multilayer electrochemically fabricated structures (e.g. fabricated by the EFAB™ formation process), and typically contain features having resolutions within the 1 to 100 &mgr;m range. The layered structure is combined with other mold components, as necessary, and a molding material is injected into the mold and hardened. The layered structure is removed (e.g. by etching) along with any other mold components to yield the molded article. In some embodiments portions of the layered structure remain in the molded article and in other embodiments an additional molding material is added after a partial or complete removal of the layered structure.

Abstract: An apparatus for manufacturing a light guide in a liquid crystal display and a manufacturing method thereof with a simplified mold structure. In the apparatus, an core material portion is fixed to a light guide molding stamper to constitute a molding device along with the stamper. A fixing member fixes the stamper to the core material portion. The molding device constitutes a mold for molding the light guide, along with a stationary core and a movable core. Accordingly, the stamper and the molding core are integrally formed and sealed, so that a mold structure can be simplified and stable manufacturing of the light guide can be provided.

Abstract: In one embodiment, a microreplication tool includes gas release features that allow gas to escape from microreplication cavities of the tool. The gas release features can be disposed at the bottoms of the respective cavities to avoid air entrapment within the cavities of the tool during the microreplication process. In this manner, the quality of the microreplicated product can be improved.

Abstract: A mask frame assembly for evaporation includes a mask and a frame which supports the mask. The mask includes a metal layer having a predetermined pattern, and a coating layer which is formed on a surface of the metal layer so as to increase a precision of the predetermined pattern and a surface roughness of the mask.

Abstract: A mold for a microlens includes a substrate at least a portion of which is electrically conductive, such as an electrically-conductive substrate or a substrate with an electrode layer, an insulating mask layer formed on the substrate and including an opening or plural openings, and a plated layer electroplated in the opening and on the mask layer. A first condition that a diameter or width (&phgr;) of the opening has a relation of &phgr;≦0.35R, wherein (R) is a radius of curvature of the plated layer right above the opening, or a second condition that the diameter or width (&phgr;) of the opening is &phgr;≦10 &mgr;m, is met.

Abstract: A method of producing a die for forming an optical element including; a positioning step to fix temporarily under the state wherein a plurality of members at least one of which has a die transfer surface are positioned with their connection surfaces being put to face each other, and an electroforming connection step to connect both members by forming an electroforming mold on a circumference of the connection surface under the state where the plural members are positioned.

Abstract: Manufacturing method for bonded electroforming metallic mold, including steps of: 1. preparation of metallic material 2. preparation of electroforming metallic plate and plastic mold core and electroforming substrate; 3. preparation of power supply; 4. forming of electroforming deposited film; and 5. final-shaping. In order to significantly shorten the electroforming time and firmly connect with the steel material of the mold, the steel material of the mold and the electroforming article are simultaneously electrically connected to the cathodes of power supplies. So, the electroforming metal is simultaneously deposited on both sides to quickly achieve the desired thickness of the electroforming metallic plate. By the metal-to-metal bonding force, the electroforming metallic plate and the steel material of the mold are firmly connected with each other. Also, the electroforming metallic plate keeps having the original cast pattern and is tightly combined with the steel material of the mold.

Abstract: This invention is a method for making purses and other bags. The first part of the process is forming a female mold of the bag. This mold can be formed in extreme detail. The mold is then preheated and colored plastic is then poured into it. The mold is then lowered into a hot oil or salt bath and the plastic and the hot oil or salt reacts causing the plastic to line the interior wall of the mold. The mold is then taken out of the hot oil or salt bath and placed in a cooling tank where the plastic is cooled and sets. The mold is taken out of the cooling tank and the unfinished bag is removed from the mold. The bag is then finished by polishing and adding any accessories such as snaps, zippers, linings, and handles to the bag. The process can be used to form a hard or soft sided bag.

Abstract: A simple, cost-effective stamping or molding in the nanometer range is enabled using a stamping surface or molding face with a surface layer having hollow chambers that have been formed by anodic oxidation.

Abstract: In a method of fabricating an array of microstructures, a substrate with an electrically-conductive portion is provided, an insulating mask layer is formed on the electrically-conductive portion of the substrate, a plurality of openings are formed in the insulating mask layer to expose the electrically-conductive portion, and a first plated or electrodeposited layer is deposited in the openings and on the insulating mask layer by electroplating or electrodeposition. A second plated layer is further formed on the first plated or electrodeposited layer and on the electrically-conductive portion by electroless plating to reduce a size distribution of microstructures over the array.

Abstract: A writable optical disc has an information writing track, and a guiding track for introducing a laser beam to the information writing track. The guiding track has prepit information recorded thereon, the prepit information including at least address information of the optical disc. The prepit information is recorded on the guiding track at a position where interference of adjacent guiding tracks with the prepit information is prevented. The information writing track is a groove track, and the guiding track is a land track.

Abstract: A method of drawing a pattern on a base material by scanning a beam, comprising: drawing a pattern including ring-shaped zones on a first pattern-drawn field on a base material by scanning a beam on a first pattern-drawn field; shifting at least one of the beam source and the base material to scan the beam on a second pattern-drawn field located next to the first pattern-drawn field in such a way that a boundary between the first pattern-drawn field and the second pattern-drawn field is positioned at a joint portion between a slope portion and a side wall portion of the ring-shaped zones; and drawing the pattern on the second pattern-drawn field by scanning a beam so that the joint portion between the slope portion and the side wall portion is drawn at the boundary between the first pattern-drawn field and the second pattern-drawn field.

Abstract: A process for producing an article with a microstructure includes the steps of forming a primary relief structure on a surface of a substrate, applying a photo resist on the substrate, exposing part of the photo resist using a photo mask so as to form a microstructure pattern, developing the microstructure pattern in the exposed photo resist, thereby allowing access to a part of the primary relief structure from the photo resist, and thereby forming a patterned surface with a microstructure relief that is bounded by the exposed part of the primary relief structure and by remainder of the photo resist on the substrate, and forming a metal layer on the patterned surface to form the article having the microstructure with a profile corresponding to the microstructure relief on the patterned surface.

Abstract: An injection mold insert and a method of fabricating an injection mold insert for molding lens molds which provides a plurality of replicates of a single master mold mandrel which may be produced, for example, by diamond point. The mandrel is used to electroform an electroform mold insert component having an optical quality surface which forms a surface of an injection mold. An adhesive is used to fixedly attach the electroform mold insert to a separately machined mold insert substrate.

Abstract: A method for manufacturing microlens light guide, which mainly includes forming patterns, in a concave or convex shape, on a plastic or wax mold substrate by mechanical processing or non-traditional processing, plasticizing the patterns to microlens patterns, as a master mold for later use, by thermal flow, electroforming to make mold core for later use, and finally injection molding to make microlens light guide.