Microstructured metal molds fabricated via investment casting

This paper describes an investment casting process to produce aluminum molds having integrated microstructures. Unlike conventional micromolding tools, the aluminum mold was large and had complex curved surfaces. The aluminum was cast from curved microstructured ceramic molds which were themselves cast from curved microstructured rubber. The aluminum microstructures had an aspect ratio of 1:1 and sizes ranging from 25 to 50 νm. Many structures were successfully cast into the aluminum with excellent replication fidelity, including circular, square and triangular holes. We demonstrate molding of large, curved surfaces having surface microstructures using the aluminum mold.