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High-speed laser chemical vapor deposition of amorphous carbon fibers, stacked conductive coils, and folded helical springs Export

edited by: James H. Smith, Jean M. Karam

Micromachining and Microfabrication Process Technology V, Vol. 3874, No. 1. (1999), pp. 227-235.

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This paper reports advances in high-pressure, 3D laser chemical vapor deposition, which may be used to prototype insulating and metallic high-aspect-ratio microstructures. In this case, carbon was grown from ethylene at pressures of 1-11 bar; fine free-standing fibers of diamond-like carbon were grown at linear rates exceeding 120,000 microns per second. This record-setting growth rate allows the computer- controlled prototyping of centimeter-scale structures in only 15-20 minutes. The volumetric growth rate is scalable in pressure and laser power so that, with a single tool, micron-size details may be deposited as readily as large objects. The morphology, diameter, and steady-state growth rate of the carbon fibers were mapped versus the input laser power, the pre-cursor pressure, and the gas flow rate. Using a rotating mandrel, helical, tapered, and folded coils were grown at rates of 10-25 micrometers /s. Flat carbon coils were also grown by steadily increasing the radius of the laser focus from the mandrel while maintaining a constant tangential velocity. Tungsten fibers and single crystals were also grown from WF6 and H2 gas mixtures.


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