Replication techniques for a metal microcomponent having real 3D shape by microcasting process

Abstract

In this paper, new replication techniques for a metal microcomponent having a real 3D shape were introduced. A helical gear was selected as one of a real 3D microcomponents for this study. The helical gear, which was made of photo-curable resin, was fabricated as a master pattern by microstereolithography (MSL) technology. Then, a silicone rubber mold was fabricated from the master pattern. Lastly, a final bismuth alloy pattern was transferred from the silicone rubber mold by the microcasting process. In this paper, the replication technique is described in detail from the master pattern to the final pattern with some investigation on factors related to the technique.