Micro-components created at Warwick

Micro-probes for bio-chemical analysis

Nano-filtration for Lab-on-a-chip applications

Probes to measure chemicals inside the Central Nervous System

3D Micro-Manufacture

Micro-manufacture is a method of building 3D parts at the Microscale, based upon a photo-polymerization process. This method can be used as an alternative to more traditional MEMS techniques. This “photo-forming” offers considerable benefits including:

• Rapid fabrication process of hours instead of days or even months,
• Short design cycles.
• Able to create true 3D structures,
• High degree of design versatility
• Low equipment and running costs

In the micro-manufacture process a Computer Aided Design or CAD drawing of the object is first produced. This 3D drawing is then sliced into a set of very thin 2D layers. These 2D slices are then fabricated one after another, like building blocks, into the photosensitive material until the finished object is formed.

3D CAD Drawing This 3D drawing is sliced These layers are reproduced Until the final
is first created; into multiple 2D layers; one after another... object is created

The Envisiontec Process at Warwick

The Envisiontec system combines a visible light source, with a shutter, a projector containing a dynamic pattern generator, and high resolution z-stage.

In normal operation a layer of photosensitive fluid is trapped between a build platform and a base platform.

The dynamic pattern generator within the projector, which contains millions of micro-sized mirrors, are orientated to reflect the visible light source into the photosensitive material, thus recreating one 2D slice of the 3D structure.

After polymerization the z-stage (with build platform) is raised, unpeeling the new formed solid object from the base platform and allowing a layer of unexposed photosensitive fluid to form a between the previously built structure and the base platform. This process is repeated until the full object is formed. Below shows the basic system components of an Envisiontec system.

The SEM photograph below shows a part fabricated through this micro-manufacture process. Here a pyramid has been formed with each new layer being one mirror (or pixel) smaller than the layer before. This photograph shows a layer thickness and a pixel dimensions of under 20 μm. With this resolution a build envelope of 27 mm x 25 mm x 50 mm+ is available.

The Sensors Research Laboratory, within the School of Engineering, University of Warwick, has worked closely with Envisiontec for a number of years.

Micro-cavities

Possible future applications...

Electronic: Micro-valves, Phase shifters Micro-pumps

Bio-tech: Micro-probes, Lab-on-a-chip, 3D cell cultivation, Medical devices, Micro-plates, reaction wells and micro/nanoliquid dispenser

Other: Ceramic microcomponents, Gas sensors, Packaging

Further test parts

As well as producing functional parts, more interesting structures can be created.

A Scooby Doo!

Homer Simpson with mug and doughnut

A rook on a 20p coin

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