Methods of and apparatus for molding structures using sacrificial metal patterns

This invention describes a way to create tiny, intricate three-dimensional objects using a mold. First, a mold is built with a temporary, "sacrificial" material that forms the desired pattern. This sacrificial pattern is typically made by layering different materials, often using a precise electroplating process where material is deposited through a mask. Once the mold is ready, a liquid material is poured into it and allowed to harden, taking the shape of the sacrificial pattern.

Why it matters: Filed in 2003, this patent predates the significant advancements in multi-material and high-resolution additive manufacturing (as classified). Modern micro-additive manufacturing techniques could now offer more flexible or cost-effective ways to create the complex sacrificial patterns and support structures originally envisioned through specialized electroplating.

Status: Not in forceListed as no longer active. The specific reason is not in the record we hold.
How hard to build: SpecializedMicro-fabrication, electroplating, patterned masks, material science

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