We are pleased to announce that we have developed a new high-resolution laser fabrication system for custom shadow masks. The system uses a focused laser beam with a spot size of approximately 600 nm and a high-precision motion stage capable of controlling each movement step to approximately 200 nm.
After extensive process optimization and testing, we can now reliably fabricate shadow masks with feature sizes down to 1 µm. Depending on the mask design and application requirements, metal foils with thicknesses ranging from approximately 10 µm to 25 µm are available.
This capability is suitable for demanding applications such as:
• Thin-film deposition
• Microelectrode fabrication
• Semiconductor research
• MEMS and microsensor development
• Micro- and nanoscale patterning
Please note that achieving a 1 µm feature size depends on the mask material, foil thickness, pattern geometry, feature spacing, and required mechanical strength. Because freestanding shadow masks must remain mechanically stable, not every complex pattern can be fabricated at this minimum feature size. Very narrow lines, long unsupported structures, and densely packed openings may deform or break during fabrication or use.
If you have a custom design, please send your drawing, CAD file, or layout to support@design-realized.com. Our engineering team will review the design, evaluate its manufacturability, and recommend the most appropriate material and thickness for your application.
