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Ultra miniature flexible circuits are highly complex devices with some amazing characteristics. Metrigraphics makes circuits with feature sizes ranging from 3 to 10 microns, some of which are so flexible they can wrap around a pencil. Some of our ultra miniature flex circuits have as many as 6 layers (although 6 is not our limit), some can withstand extreme mechanical loads, and some can perform [...] Read More
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In an earlier blog post we discussed why micron-scale thin film circuits perform better when made using an additive versus a subtractive process. The additive process defines circuit lines by adding (electroplating) conductive material on top of a thin metal film that’s been fully-sputtered onto a substrate. The places where metal is added are defined by a stencil of photoresist [...] Read More
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Device makers have a choice of whether to specify an additive or subtractive process for fabricating the micron-scale circuits used in their products. Knowing the basic differences between the two is important. Choosing the right one can make a big difference in whether a circuit will perform as required. In general, an additive thin film process is much more likely to achieve: - Higher circuit [...] Read More
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Medical design is increasingly impacting miniaturization. Testament to this, as a micron-scale process developer and manufacturer, we’re receiving more and more requests from biosensor and device designers looking to push the limits. Circuits now need to bend and carry added functionality, and line traces and spaces are becoming smaller and tighter. This challenges us to push our own [...] Read More
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Does your product or application call for a very tiny part?  If so, nano-scale electroforming may be your best or even your only option. To find out for sure you’ll need to talk to someone with expertise and experience in this highly specialized field of manufacturing. To get that discussion started, here’s some background on the key factors that help determine nano-scale electroforming [...] Read More
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Are you looking for a reliable photolithography partner? At Metrigraphics, our proprietary photolithography process ensures that you get more consistent trace definition, thinner and therefore more flexible circuits (where needed) AND more uniform circuit lines (i.e., same width top and bottom).  Our process defines patterns at extremely fine resolutions on substrates that range in size [...] Read More
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For more than 50 years we've been a trusted supplier of precise optical components for motion control, analytical instrumentation, test and other optics markets — all designed and manufactured to impossibly high standards of precision and reliability. We design and fabricate ultra-small, micron-scale optical components that include: Rotary discs and linear encoder scales, Test targets, [...] Read More
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Giving Our Customers What They Want Metrigraphics’ customers have very high standards when it comes to selecting the source of their electroformed parts. They look for extreme capabilities in areas like: • Feature size • Feature controllability • Surface uniformity • Batch consistency • Component ruggedness In other words, our customers want parts [...] Read More
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The Making of Ultra-Precise, Ultra-Small Three-Dimensional Structures Precision electroforming is an additive process in which 2-D and 3-D microstructures are formed by electrochemically depositing metal into a precisely formed photoresist mold. Electroforming is ideal for fabricating micron-scale, metallic components as well as for making injection molds used for forming nonmetallic microstructures [...] Read More
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Though a medical device designer may be an expert in the specific application and sensing technology employed in a device, this expertise does not necessarily translate to building that technology on a large scale with stringent reliability constraints. Moreover, because the variables and potential combinations are difficult to define, so to are standard design guidelines. Conventional flex circuits [...] Read More
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Though a device designer may be an expert in knowing the specific technology needed in a device, this expertise does not necessarily translate into knowing how to design and produce the necessary circuitry for the size, reliability, and mass production requirements that are critical to the new device’s success. Here are 3 quick tips to keep in mind when approaching the design of an ultra-small [...] Read More
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The ultimate factor in deciding when not to use the Kapton polyimide film manufacturing method is a combination of desired size and flexibility. Basically, the moment you’re uttering “micron” as opposed to “mils”, best to start thinking about thin film. Conventional flex circuit manufacturing often starts with rolls of Kapton — a Dupont™ polyimide film pre-clad [...] Read More
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Electroforming, electrochemical machining (ECM), and electrical discharge machining (EDM) all use electrolytic baths. But only one is additive, which helps explain why it’s best for nano-scale components and structures.  Electrolytic baths have a long history as a way to add very thin layers of material to a target metal, as in silver or gold plating, or to remove material through electrolysis, [...] Read More
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Micron-scale flexible circuits from Metrigraphics can be produced in multi-layers and with circuit lines as narrow as 3 microns. They’re flexible enough to wrap around small objects and are durable enough for harsh MIL-COM environments. Circuits are achieved via high-resolution photolithography, as well as sputtered thin-film and plated metal deposition techniques. Multilayer flexible circuits [...] Read More
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Knowing how to more effectively source small parts at high yields is a key success factor for medical OEMs looking to pack highly innovative designs into very small products.   We are receiving a lot more inquiries these days from medical OEMs. These companies are busy turning a growing backlog of scientific innovations into marketable products that will advance healthcare and grow businesses. [...] Read More