Sandia Corporation

Sandia National Laboratories

Patrick N Keifer

Alfredo M Morales

Linda Domeier

Terry Joseph Garino

Marcela G Gonzales

Leroy L Whinnery, Jr

Dawn M Skala

Steven Howard Goods

Craig C Henderson

Disclosed is a method for making a polyurethane closed-cell foam material exhibiting a bulk density below 4 lbs/ftand high strength. The present embodiment uses the reaction product of a modified MDI and a sucrose/glycerine based polyether polyol resin wherein a small measured quantity of the polyol resin is 'pre-reacted' with a larger quantity of the isocyanate in a defined ratio such that when the necessary remaining quantity of the polyol resin is added to the 'pre-reacted' resin together with a tertiary amine catalyst and water as a blowing agent, the polymerization proceeds slowly enough to provide a stable foam body.

Method for providing a low density high strength polyurethane foam

A compliant cantilevered three-dimensional micromold is provided. The compliant cantilevered micromold is suitable for use in the replication of cantilevered microparts and greatly simplifies the replication of such cantilevered parts. The compliant cantilevered micromold may be used to fabricate microparts using casting or electroforming techniques. When the compliant micromold is used to fabricate electroformed cantilevered parts, the micromold will also comprise an electrically conducting base formed by a porous metal substrate that is embedded within the compliant cantilevered micromold. Methods for fabricating the compliant cantilevered micromold as well as methods of replicating cantilevered microparts using the compliant cantilevered micromold are also provided.

Method for providing a compliant cantilevered micromold

Compliant cantilevered micromold

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Livermore, CA, United States of America

Patrick N Keifer