US Patent 12599757B2 - Fabrication Method for Complex 3D Microscale Structures
Summary
The USPTO granted Patent 12599757B2 to The Charles Stark Draper Laboratory, Inc. on April 14, 2026, covering a bilayer mold fabrication method for forming polymer and metal microstructures. The invention enables creation of complex re-entrant 3D microscale structures using laser-etching of metallic foil and plastic elastic polymer materials. Six claims were granted.
What changed
The USPTO granted Patent 12599757B2 to The Charles Stark Draper Laboratory for a bilayer mold fabrication method enabling complex re-entrant 3D microscale structures. The invention combines rigid plastic cylinder molds with plastic elastic polymer layers and laser-etched metallic foil to form precise microstructures. The structures can be applied to stent surfaces to facilitate retention.
Manufacturers developing polymer or metal microstructures for medical devices should review this patent to assess potential licensing needs or design-around considerations. The patent claims bilayer mold configurations and laser-etching methods for forming microstructures on medical device surfaces.
Archived snapshot
Apr 18, 2026GovPing captured this document from the original source. If the source has since changed or been removed, this is the text as it existed at that time.
Fabrication method for complex, re-entrant 3D microscale structures
Grant US12599757B2 Kind: B2 Apr 14, 2026
Assignee
The Charles Stark Draper Laboratory, Inc.
Inventors
Daniel Frederick King, David J. Carter, Corin Williams, Stephanie Lynne Golmon
Abstract
A bilayer mold for forming polymer microstructures is provided. The bilayer mold includes a rigid plastic cylinder having slots defined along an outer periphery of the rigid plastic cylinder; and a layer of plastic elastic polymer material disposed within the slots and having indents defined therethrough and in the rigid plastic cylinder. The indents have a first profile extending through the layer of plastic elastic polymer and terminating within the rigid plastic cylinder. A metal polymer structure profile is also provided using laser-etching of a desired shape for the features of the microstructures in a metallic foil, followed by further refining of the features. The polymer and metal microstructures can be formed on the surface of a stent to facilitate retention of the stent.
CPC Classifications
A61M 37/0015 A61M 2037/0053
Filing Date
2024-02-02
Application No.
18431205
Claims
6
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