WAFER-SCALE, SOLID FREEFORM FABRICATION OF FULLY-ASSEMBLED METAL MICRO-MECHANISMS FOR MINIMALLY-INVASIVE MEDICAL
Solid Freeform Fabrication Symposium Proceedings. Solid Freeform Fabrication Symposium
|October 7, 2014
Summary
The Electroforming Fabrication (EFAB) process now produces complex 3D devices at scale. This advanced manufacturing method utilizes biocompatible metals for innovative surgical instruments.
Area of Science:
- * Materials Science and Engineering
- * Mechanical Engineering
- * Biomedical Engineering
Background:
- * The Electroforming Fabrication (EFAB) process, introduced in 1998, has evolved significantly.
- * Early development stages focused on foundational principles.
- * Current capabilities enable large-scale production of intricate devices.
Purpose of the Study:
- * To detail the advancements and current state of the EFAB technology.
- * To highlight the manufacturing capabilities and precision achievable with EFAB.
- * To underscore the potential applications of EFAB-produced devices in medical fields.
Main Methods:
- * A three-step process involving selective and blanket electrodeposition of metals.
- * Planarization techniques to achieve high precision.
- * Utilization of biocompatible metals with properties comparable to stainless steel.
Main Results:
- * Production of complex, pre-assembled 3D mechanisms in volume.
- * Achieved layer thickness as low as 4 μm.
- * Minimum feature size down to 10 μm with linear tolerances around 2 μm.
Conclusions:
- * EFAB technology is a mature, scalable manufacturing solution.
- * The process yields high-precision, biocompatible components.
- * EFAB enables the development of novel instruments for minimally-invasive surgery.
