3D Metallized Pattern Manufacturing via Electroforming
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Solution Overview
Problem
Existing methods for producing decorative components for timepieces and jewelry struggle to create complex, precise, and controlled three-dimensional metallized patterns, as they are either complex and slow or fail to produce clean, three-dimensional shapes effectively.
Innovation Solution
A method involving the formation of three-dimensional enamel patterns on a substrate, followed by the deposition of a structured metal layer, using sintered enamel and photosensitive resins to achieve clean and complex three-dimensional metallized patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If PVD and electroforming are used to create deep markings, then decorative patterns can be produced, but the process becomes complex and slow
Solution Approach 1:
The process is segmented into distinct stages: creating recesses in the substrate, depositing conductive layer, applying photosensitive resin, photolithographic patterning, and electroforming. This segmentation allows each step to be optimized independently and simplifies the overall process control.
Solution Approach 2:
The conductive layer is deposited on the substrate before the electroforming step, preparing the surface in advance. The photosensitive resin is applied and patterned before the actual metal deposition, allowing precise definition of the decorative pattern geometry prior to material addition.
2Manufacturing precision
If thin layers are deposited by PVD, then conductive layers can be formed, but satisfactory three-dimensional decorative patterns cannot be produced
Solution Approach 1:
The structure is built in nested layers: the conductive layer is deposited first, then the photosensitive resin is applied over it, followed by the metal layer during electroforming. This nested arrangement allows the thin conductive layer to serve as a foundation for building three-dimensional decorative patterns through subsequent material deposition.
Solution Approach 2:
The process transitions from two-dimensional thin film deposition to three-dimensional pattern formation by using photolithographic masking and electroforming to build up metal structures with vertical depth, creating raised or recessed decorative elements on the substrate surface.
3Manufacturing precision
If galvanic growth or electroplating is used with photosensitive resin masking, then decorative patterns can be produced, but precise and mastered three-dimensional shapes are difficult to obtain
Solution Approach 1:
The photolithographic process provides feedback control for the electroforming step. The developed photosensitive resin pattern serves as a precise mask that defines exactly where metal should be deposited, allowing real-time control over the three-dimensional shape formation during electroforming.
Solution Approach 2:
The mechanical masking approach is replaced with photolithographic patterning using photosensitive resin and UV exposure. This substitution enables more precise and flexible pattern definition, allowing complex three-dimensional shapes to be controlled through optical processes rather than mechanical masking methods.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the easy production of three-dimensional metallic decorative patterns with complex, precise, and controlled shapes, utilizing inert and high-temperature-resistant metallized enamel, improving upon the limitations of previous techniques.
Implementation Method 1
depositing a layer of photosensitive resin; then in placing on the photosensitive resin a mask around the outline of the upper portion and of the pattern of the decoration to be produced; then in exposing the resin to radiation through the mask, so as to develop some portions of the resin
Implementation Method 2
the hollows are filled with a metal by electroforming by immersing the part in a bath of metal ions, then an electric current is circulated in this bath. Thus the hollows are filled with metal to carry out the marking
Implementation Method 3
which comprises the features mentioned in independent claim 1... one or more enamel pattern(s) (3) are formed, beforehand, in three dimensions on a substrate (6)
Data Source
AI summary
The present invention relates to a method for manufacturing a part comprising at least one three-dimensional metallised pattern overlying a local enamel underlayer.