Mr. Dean J. Guidry Profile

Dean J. Guidry

Microsystems Design Engineer at Mezzo Systems Inc

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Proceedings Article | 15 January 2003 Paper

Embossing of microscale features in Pb and Zn

Dean Guidry, Dong Mei Cao, Tao Wang, Wen Jin Meng, Kevin Kelly

Proceedings Volume 4979, (2003) https://doi.org/10.1117/12.472758

KEYWORDS: Nickel, Zinc, Lead, Metals, Scanning electron microscopy, X-rays, Fabrication, Plasma, Ceramics, Polymethylmethacrylate

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Embossing of microscale features into Pb and Zn was carried out using LIGA (Lithographie, Galvanoformung, Abformung) fabricated Ni mold inserts with features 100 microns in diameter and 500 microns in height. Molding was carried out at 300 °C with both uncoated Ni inserts and Ni inserts coated with Ti-containing hydrocarbon (Ti-C:H). The coatings were applied using a high-density inductively coupled plasma (ICP) assisted hybrid chemical vapor deposition (CVD)/physical vapor deposition (PVD) technique. This technique is shown to produce coatings conformally onto LIGA fabricated high aspect ratio microstructures (HARMs). The performance of the molding process was characterized using scanning electron microscopy (SEM) and energy-dispersive x-ray spectroscopy both in terms of the features generated and the insert condition after molding. The present results indicate that in molding metals that are not reactive with Ni no coating is necessary to produce the microfeatures. This study also demonstrates that in molding Zn, where significant metal/insert chemical interactions exist, surface engineering of the mold insert is necessary to obtain satisfactory performance. Conformal deposition of engineered ceramic coatings onto Ni microscale mold inserts is an effective means for achieving micromolding of reactive metals.

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