High-Density Shadow Mask Fabrication for 3D Substrates
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Solution Overview
Problem
The challenge lies in manufacturing and integrating electronic components onto complex, three-dimensional substrates like contact lenses, which require precise interconnects and features on non-planar surfaces while maintaining optical clarity and comfort, due to the difficulty in mounting and interconnecting components on a curved surface and the need for miniaturization within a small area.
Innovation Solution
A method for creating high-density shadow masks using a mandrel with machined forms corresponding to the substrate shape, where shadow mask blanks are electroplated and then machined to form precise patterns, allowing for the deposition of materials on three-dimensional substrates with features smaller than 1 micron, enabling efficient and precise interconnects on non-planar surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional masking techniques are used on three-dimensional substrates, then the manufacturing process is simpler, but the manufacturing precision deteriorates due to inability to maintain precise patterns on non-planar surfaces
Solution Approach 1:
The mandrel is pre-machined with the exact three-dimensional form corresponding to the substrate shape before mask fabrication. This preliminary action ensures that when the mask is formed on the mandrel and subsequently transferred to the substrate, the pattern precision is maintained throughout the process, resolving the contradiction between precision and complexity.
Solution Approach 2:
A mandrel serves as an intermediary object between the mask fabrication process and the final substrate. The mandrel with its pre-machined three-dimensional form acts as a mediator that enables precise pattern transfer to non-planar surfaces, achieving high manufacturing precision while managing process complexity through a dedicated intermediate tool.
2Quantity of substance
If features are made smaller to increase integration density, then the functionality increases, but the manufacturing precision requirement becomes more stringent and difficult to achieve
Solution Approach 1:
Traditional mechanical lithography methods are replaced with deposition through shadow masks. This substitution enables precise feature formation at smaller dimensions by using the shadow mask's physical structure to define patterns, achieving higher integration density while maintaining control over feature size through the mandrel's pre-machined geometry.
3Manufacturing precision
If additional post-processing steps are added to achieve precise features, then the manufacturing precision improves, but the productivity deteriorates due to increased process time
Solution Approach 1:
The mandrel is pre-machined with the exact three-dimensional form and pattern requirements before mask fabrication. This preliminary action embeds the precision requirements into the tooling itself, allowing direct deposition of precise features without subsequent post-processing steps, thereby maintaining high manufacturing precision while improving productivity through process integration.
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 allows for the fabrication of precision masks that can form detailed features on complex three-dimensional substrates, such as ophthalmic devices, with high precision and repeatability, overcoming the limitations of conventional masking techniques by enabling precise material deposition and reducing the need for additional post-processing, thus enhancing the functionality and comfort of wearable electronics.
Implementation Method 1
forming one or more shadow mask blanks in the one or more forms in the mandrel; removing the one or more shadow mask blanks from the mandrel; and machining a predetermined pattern into the one or more shadow mask blanks to form one or more shadow masks
Data Source
Figure 1A~1C
Figure 2A~2C
Figure 3A~3D
AI summary
A method for fabricating high-density masks for non-planar or three-dimensional substrates utilizes a mandrel (100) having one or more precision forms (102) machined therein. Once the mandrel (100) with one or more forms (102) is fabricated, one or more mask blanks (108) may be constructed thereon. The final masks may be cut from one or more mask blanks (108).