Precise Micropatterning on Metal Surfaces

NineSigma, representing a Global Leader in medical devices, invites proposals for technologies that can create micron scale structures on metal surfaces. The challenge is to obtain a robust micropatterned surface with a high aspect ratio that can maintain the surface characteristics in a high pressure, high temperature environment.  The approach must be applicable to curved (non planar) metal surfaces.

Microstructures on the surfaces of medical devices have many advantages for the various medical application. Surface patterning imparts critical functional features to the device, such as anti-fouling, hydrophobicity, adhesion, etc. The RFP sponsor is seeking innovations that allow creating precise microstructured patterns on non-planar metal surfaces.

The technology must:

• Be able to create micropatterns on metal surface with desired pattern height (Z – perpendicular to metal surface) and pattern size (XY- on metal surface) less than 10 µm size.
• Be able to create micropatterns with surface roughness less than 1/10 of the feature height.
• Be able to create micropatterns on non-planar (such as hemispherical) metal surface with patterned area greater than 1 cm².
• Be able to create micropatterns that can withstand temperature up to 250 C and pressure up to 50 MPa.
• Be able to create micropatterns that can withstand many temperature and pressure cycles.

Preferred features

• Can create micropatterns with high aspect ratio features; height/characteristic feature length ~ 1 – 3.
• Can create vertical features with vertical walls less than 10º with normal direction to the metal surface.
• Can create micropatterns on metal surfaces, such as aluminum, nickel-bronze alloy, or nickel coated metals.
• Can verify feature dimensions created on the metal surface accurately.

Possible approaches might include, but are not limited to:

• Micromachining Techniques
• Lithography Techniques
• Chemical or Electrochemical Etching Techniques
• Physical or Chemical or Electrochemical Deposition Techniques

The following approaches are not of interest:

• Glass, plastic/polymer, or exotic materials on which the pattern is then produced
• Established methods that cannot improve upon the current limitations listed here for micropatterned metal surfaces

Your response should address the following:

• Non-confidential description of proposed technology and working principle
• Availability of technical data
• Technical maturity of the approach (concept, reduced to practice, prototype, ready to commercialize, ready to implement, commercialized)
• Pathway to commercial scale including timing, estimated budget, and capacity for manufacture
• Position on intellectual property including patent references
• Desired relationship with sponsor
• Team description and related experience