Categories: Manufacturing, Adhesion
This page describes the process of casting adhesive features on flexible Kapton backings. Molds can be manufactured via micromachining, or may be a daughter mold, but must have geometry defining the reference flat with wax, and not tape pillars.
Fixture the Kapton Film
- Locate one of the porous ceramic tiles, and place it on a paper towel, lapped side up. Wipe with a dry Kimwipe to ensure the surface is dust-free.
- Cut a square of Kapton film approximately 6.5" square. Clean one surface of dust with a Kimwipe wetted with acetone.
- Locate the container of methyl cellulose; this is a 1:30 by mass solution of pure methyl cellulose in water. The resulting gel-like glue is completely non-toxic, and readily dissolves in water after being dried.
- Use a glass stir rod to spread a reasonable amount of methyl cellulose gel across the middle of the ceramic tile.
- Carefully lay the Kapton sheet over the tile, ensuring it overlaps all four edges, and that the clean side is down.
- Wipe the top surface of the Kapton lightly with a Kimwipe to remove dust.
- Place the steel dowel pin on the Kapton, in the middle of the glue. It should be in position to squeeze half the glue in each direction.
- Applying firm downward pressure, roll out the Kapton film until flat. Some glue should squeeze out all four edges. Take care to keep glue from squeezing onto the roller or top surface of the Kapton.
- Slide the tile on the paper towel to the edge of the table, place a cleaned 12x12x0.375" glass plate on top.
- Flip the assembly, then carefully remove the paper towel.
- Set a weight on the back, and let the glue dry for about 24 hours.