Batch Micromechanical Metal Parts Galvanic Mold Machining
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Solution Overview
Problem
Existing methods for manufacturing micromechanical metal parts using electroplating require tedious and expensive retouching, as each part must be individually mounted for mechanical machining, which is time-consuming and inefficient due to the small size of the parts.
Innovation Solution
A method combining LIGA technology with multiple mechanical machining steps, allowing for in-situ machining of both the upper and lower surfaces of the metal parts before separation from the mold, reducing the need for extensive handling and using a robust substrate for initial machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electroplating is used to manufacture micromechanical metal parts, then manufacturing precision is improved, but productivity deteriorates due to time-consuming individual mounting and retouching
Solution Approach 1:
The machining process is segmented into two distinct stages: first machining the upper surface while parts are in the mold, and second machining the lower surface after releasing parts from the mold. This segmentation allows different machining operations to be performed on different surfaces at different times, resolving the contradiction between precision and productivity.
Solution Approach 2:
The upper surface machining is performed as a preliminary action while the parts are still in the mold, before the parts are released and require individual mounting. This preliminary machining reduces the subsequent retouching work needed after individual mounting, thereby improving overall productivity while maintaining precision.
2Manufacturing precision
If mechanical machining is performed after releasing parts from the mold, then manufacturing precision is maintained, but loss of time increases due to individual mounting requirements
Solution Approach 1:
Machining of the upper surface is performed as a preliminary action while parts are still in the mold and before individual mounting is required. This eliminates the time loss associated with mounting for the first machining operation, while the second machining operation after release ensures final precision is achieved.
Solution Approach 2:
The mold serves as an intermediary structure that enables batch machining of the upper surface. By keeping parts in the mold during first machining, the mold acts as a mediator that allows simultaneous processing of multiple parts without requiring individual mounting, thus reducing time loss while maintaining precision through subsequent second machining.
3Ease of operation
If only upper surface machining is performed in the mold, then ease of operation is improved, but adaptability deteriorates as lower surface machining becomes inaccessible
Solution Approach 1:
The machining operation is segmented into two separate stages: first machining the upper surface while parts are in the mold (easy access), and second machining the lower surface after parts are released from the mold (also accessible). This segmentation allows both surfaces to be machined with ease of operation while achieving full adaptability for multi-surface machining.
Solution Approach 2:
The conventional sequence is inverted: instead of mounting individual parts for all machining operations, the method first machines the upper surface while parts are in the mold (batch processing), then releases parts, and finally machines the lower surface. This inversion of the conventional approach provides both ease of operation and adaptability for multi-surface machining.
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 approach significantly reduces time and costs by enabling efficient machining of both surfaces during the manufacturing process, allowing for complex shapes without the need for multiple layers of photosensitive resin, while ensuring strong adhesion and stability during machining.
Implementation Method 1
depositing a layer of photosensitive resin on the substrate and structuring it in order to manufacture a mold comprising cavities
Implementation Method 2
filling the cavities with metal of the mold by galvanic deposition so as to form a metal part
Data Source
Figure 1~5
Figure 6~10
Figure 11~13
AI summary
The process comprises the steps of: - making a single-level polymerized resin mold (6) on a substrate (2); - forming metal parts (10) by galvanic growth in the cavities (8) of the mold from the upper face (4) of the substrate acting as a cathode; - releasing the structure (12) formed by the mold and the metal parts it contains from the substrate (2); - fixing the structure (12) on a support (14) in an inverted position, so that the upper surface of the structure is facing the support and the lower surface is exposed; - mechanically machining the lower surface of the structure (12); - releasing the metal parts (10) from the support (14) and the mold.