Rapid fabrication of microcomponents

In the macroscopic world different "rapid "-technologies like Rapid Prototyping, Rapid Manufacturing or Rapid Tooling have been established for a fast prototype or molding tool development. In all cases CAD-data can be transformed in a model or prototype directly using a laser which polymerizes reactive resins layer by layer to a final 3D mold within a short period. In this work the rapid fabrication of microcomponents made from polymers or composites will be presented. The whole fabrication process is divided into two main steps: Firstly laser assisted micromachining using Nd:YAG and KrF-Excimer laser allows a rapid manufacturing of microstructured cemented carbide or steel mold inserts. Secondly the application of light induced reaction injection molding using reactive monomer/polymer resins gives access to the replication of the previously fabricated mold insert. The total processing period starting from CAD until the molded microstructured part is less than one week.