TECHNICAL FIELD
The present disclosure relates to a counter template mold for the preparation of mold of empty
recipient tissue microarray (TMA) block and to a method for preparing a counter template mold
for the preparation of mold of empty recipient TMA block. More particularly, the present
disclosure relates to a metal or polymer counter template mold of recipient TMA block and to a
method for preparing a metal or polymer counter template mold for the preparation of empty
recipient TMA block by making a counter template of mold.
BACKGROUND
A tissue microarray (TMA) block is an ordered array of biological tissues numbering 20-1000
and placed on a paraffin wax or epoxy resin or any other suitable material. The biological tissues
can be human, animal, plant, and cultured cells. TMA blocks are constructed by transferring
tissues of 0.1 mm to 10 mm diameter size from Donor Tissue block to Recipient TMA block
consisting of empty arrays of same size. Empty Recipient TMA block can be made by inserting
a hollow needle of 0.1 mm to 10 mm size as required, to remove the paraffin wax or epoxy resin
from recipient TMA block.
Alternative method to prepare a recipient TMA block is to make a mold of defined array. The
mold can be made of silicone, epoxy resins, etc. However, the limitation associated with said
molds is that the mold for empty recipient TMA block may lose its integrity after making few
recipient TMA blocks. This may be due to material used for making the mold and wear and tear.
Hence, multiple molds need to be made. But the method of making molds repeatedly is
problematic as it is tricky and involves a great quantity of time and labour. The present disclosure
aims to provide a solution to the aforesaid limitations of prior art by providing a method of
making a sturdy metal or polymer counter mold by making use of a counter template of mold
and three-dimensional printing (3D) or micromachining technique. The counter template of
mold enables making multiple molds. Thus, the present method of making a mold can be
automated and hence multiple molds may be produced by using the same counter-template.
Automation will decrease cost of production of molds, and eventually TMA block and TMA slides for
analysis of nucleotides like DNA, RNA and oligo- and poly- peptides, proteins, fat, carbohydrate and
metabolites. Most importantly, the variation among the prepared molds is limited as same
counter-template is used.
Currently, methods of making counter template of mold for recipient TMA block are not
documented. It is anticipated that mold may be etched into them by drilling methods or
punching. Such drilling methods or punching will cause batch variations in making molds due to small
dimensions in which drilling or punching methods are to be performed. Also, such variations will increase
the cost of production.
Thus, the present disclosure successfully provides a method of making a metal or polymer
counter template mold for the preparation of mold used to make empty recipient TMA block
using a counter template of mold design and hence sturdy metal or polymer counter template
molds of molds to make recipient TMA block.
Description:SUMMARY OF THE DISCLOSURE
The present disclosure relates to a method of preparing a counter template mold of mold used for the preparation of empty recipient tissue microarray (TMA) block, comprising:
a)
creating a computer aided design (CAD) of counter template of mold of a recipient TMA block of suitable dimensions;
b)
providing the output of the CAD design of step a) to a micromachining unit or 3D printer to obtain a metal or polymer counter template mold of mold of a recipient TMA block; wherein the output of the CAD design of step a) is fed to a micromachining unit to obtain a metal counter template mold of mold of the empty recipient TMA block; or wherein the output of the CAD design of step a) is fed to a 3D printer to obtain a polymer counter template mold of mold of the empty recipient TMA block.
The present disclosure further relates to a counter template mold of metal or polymer for the preparation of mold of recipient TMA blocks.
BRIEF DESCRIPTION OF FIGURES
In order that the disclosure may be readily understood and put into practical effect, reference will now be made to exemplary embodiments as illustrated with reference to the accompanying figures. The figures together with a detailed description below form a part of the specification, and serve to further illustrate the embodiments and explain various principles and advantages,
in accordance with the present disclosure wherein:
Figure 1 shows the front view of design template of counter-template mold wherein the numbers in figure indicate dimensions in mm; Figure 1a shows 3D view of design template of counter-template mold and Figure 1b shows side view of design template of counter-mold wherein the numbers in figure indicate dimensions in mm.
Figure 2 shows the flowchart of preparation of design of counter template of mold in CAD software.
Figure 3 shows the front view of 3D printing in process; Figure 3a shows the top view of 3D printing in process.
Figure 4 shows the front view of the 3D printer, WOL3D ENDER; Figure 4a shows the 3D printer: WOL3D ENDER (stage)
Figure 5 shows the Counter Template Mold made after 3D printing process.
Figure 6 shows the Micromachining process (stage); Figure 6a shows the Micromachining process wherein metal template is used.
Figure 7 shows the Micromachining process; Figure 7a shows the Micromachining process with finished product.
Figure 8 shows the Counter Template Mold made after micromachining process.
DETAILED DESCRIPTION OF THE DISCLOSURE
As used herein, the term/phrase ‘counter template mold’ refers to a product with design that is complementary in dimensions to that of the mold and has same/similar dimensions as that of the product of mold.
As used herein, the term/phrase ‘Three-dimensional (3D) printing’ refers to a number of manufacturing technologies that generate a physical model from digital information; the term/phrase ‘Micromachining’ refers to the fabrication of micromechanical structures with the help of etching techniques to remove unwanted part from the substrate or thin film. Two major
techniques used in micro machining are Additive method (e.g. Inkjet) and Subtractive method (e.g. Laser printing, spark printing, CNC wire cutting and Electric Discharge Micromachining (EDM)).
The present disclosure relates to a method of preparing a counter template mold of mold used for the preparation of empty recipient Tissue microarray (TMA) block, comprising:
a)
creating a computer aided design (CAD) of counter template of mold of a recipient TMA block of suitable dimensions;
b)
providing the output of the CAD design of step a) to a micromachining unit or 3D printer to obtain a metal or polymer counter template mold of mold of a recipient TMA block; wherein the output of the CAD design of step a) is fed to a micromachining unit to obtain a metal counter template mold of the empty recipient TMA block; or wherein the output of the CAD of step a) is fed to a 3D printer to obtain a polymer counter template mold of the empty recipient TMA block.
In an embodiment of the present disclosure, the design of counter template of mold comprises the steps of:
a)
Open modeling software;
b)
Open part modeling tool in the CAD software;
c)
Select a plane for sketching;
d)
Sketch a rectangle (R1) having dimensions (length L1 and breadth B1);
e)
Extrude the rectangle to convert the sketch of the rectangle into a rectangular block, wherein the dimension of height is H1;
f)
Draw three rectangles R2, R3 and R4, wherein the dimensions of R2 are (length L2 and breadth B2), dimensions of R3 are (length L3 and breadth B3), dimensions of R4 are (length L4 and breadth B4);
g)
Select two rectangles, R2 and R3, remove material between these two rectangles using Extrude/Cut/Relevant option in the software up to depth H2 to form a rectangular grove and a central rectangular projection;
h)
Select two rectangles, R3 and R4, remove material between these two rectangles, using Extrude/Cut/Relevant option in the software up to depth H3 to form a rectangular step below the central rectangular projection;
i)
Using rectangle R4 remove material up to depth equal to H4;
j)
Add a chamfer at rectangular locations corresponding to R1, R2, R3 and R4, wherein Chamfer at ‘A’ degrees is preferred but the angle can vary, and the chamfer length is ‘C’ and wherein the said step is optional, as adding this feature will give a better ergonomic design;
k)
Add fillet to all the grove edges with Fillet radius ‘F’, wherein the said step is optional as adding this feature will give a better ergonomic design;
l)
Sketch a circle at the location of the positional hole preferably at one of the corners of the rectangular protrusion, wherein the diameter of the hole is ‘D’;
m)
Extrude this circle and remove the material to create a positioning hole, wherein the Depth of the hole is H5;
n)
Add a chamfer or fillet to the positioning hole, wherein the said step is optional, addition of a chamfer or fillet will improve ease of positioning, wherein the Chamfer at 45 degrees is preferred but the angle can vary, wherein the chamfer length is ‘C’; or fillet radius is ‘F’;
o)
Sketch a circle at the corner location of the array of holes wherein the diameter of the hole is ‘D’;
p)
Extrude this circle and remove the material to create a hole, wherein the Depth of the hole is H5;
q)
Add a chamfer or fillet to this hole, wherein Chamfer at 45 degrees is preferred but the angle can vary, wherein the chamfer length is C; Or fillet radius is F;
r)
Create an array of holes (along with the chamfer or fillet) to form the matrix of holes by giving the offset dimension center to center (O) and number of holes along the length (Nx) and width (Ny);
s)
Optionally, the chamfer or fillet at the top edge of each hole can be given after creating the array of holes;
t)
The modeling order of a few steps can be interchanged, for example, steps for positional hole and array of hole can be interchanged; and
u)
Save the CAD file.
This procedure can be adapted using any available CAD software and using features specific to the software.
In an embodiment of the present disclosure, the design of counter template of mold applied to CATIA V5R19 software comprises the steps of:
a)
Open CAD software, CATIA V5R19;
b)
Start> Mechanical design> Part design;
c)
Select X-Y plane;
d)
Sketch> Centered rectangle (R1);
e)
Give thickness (H1) to drawn rectangle using option Pad;
f)
Select X-Y plane;
g)
Sketch > Centered rectangle – draw two rectangles (R2 and R3);
h)
Create grove using Pocket option upto depth H2;
i)
Sketch > Centered rectangle – draw two rectangles (R3 and R4);
j)
Create step using Pocket option up to depth H3;
k)
Sketch > Centered rectangle (R4);
l)
Remove material up to depth H4 using option Pocket option;
m)
Add Fillet/Chamfer in the Dress-Up Features toolbar to the six dominant rectangular edges, wherein the said step is optional and wherein the Dimensions – are Fillet radius F, chamfer length C, chamfer angle A;
n)
Create positioning hole using Hole feature in CATIA, wherein Hole diameter is D and depth is H5;
o)
Add Fillet/Chamfer in the Dress-Up Features toolbar to the top edge of the positioning hole, wherein the Dimensions are - Fillet radius F, chamfer length C, chamfer angle A;
p)
Create the first hole of the array of holes using Hole feature in CATIA wherein the Hole diameter is D and depth is H5.
q)
Create array of holes using Rectangular Pattern feature in CATIA. Wherein the Offset dimension is (O) and number of holes along the length is (Nx) and width is (Ny);
r)
Add a chamfer or fillet to these holes using Fillet/Chamfer in the Dress-Up Features toolbar;
s)
The modeling order of a few steps can be interchanged, for example, steps for positional hole and array of hole can be interchanged;
t)
Save the file as .CAT Product; and
u)
Export the file for printing in required format (e.g *.igs format).
The same procedure can be applied across different software versions of CATIA as well.
In another embodiment, the design of counter template of mold saved as .igs format in step a) is converted into .stp file format in step b) for micromachining to obtain a metal counter template mold of mold of a recipient TMA block.
In still another embodiment, the design of counter template of mold saved as .igs format in step a) is converted into .stl format in step b) for feeding into a 3D printer to obtain a polymer counter template mold of mold of a recipient TMA block. Essentially, after the design is converted into .stl format, command is given to the 3D printer for printing. G-code file containing instructions is created from .stl file. The 3D printer then follows this instruction from G-code file to build a counter-mold by putting down successive layers of material (polymer).
In another embodiment, the counter template mold has a rectangular shape denoted by (R1). Further the inner rectangular shape present inside R1 is denoted by (R2), the inner rectangular shape present inside R2 is denoted by (R3) and the inner rectangular shape present inside R3 is denoted by (R4), wherein the range and the preferred dimensions of length, breadth and height of rectangles R1, R2, R3, and R4 are provided in Table 1 below. Furthermore, the features such as chamfer angle (A), Chamfer length (C), Fillet radius (F), Diameter of Hole (D), Hole depth (H5), Offset dimension (O) and Number of holes in array (Nx and Ny) are also provided in Table 1 below.
Table 1:
Feature
Minimum dimension (mm, if not mentioned otherwise)
Maximum dimension (mm, if not mentioned otherwise)
Dimension used in the current embodiment (mm, if not mentioned otherwise)
Rectangle (R1)
Length (L1)
2.5
100
58
Breadth (B1)
2.0
75
37
Height (H1)
0.5
30
14
Rectangle (R2)
Length (L2)
2.0
95
54
Breadth (B2)
1.5
70
33
Height (H2) from
0.3
20
10
top
Rectangle (R3)
Length (L3)
1.2
78
42
Breadth (B3)
7
54
23
Height (H3)
0.1
5
2
Rectangle R4
Length (L4)
10
76
40
Breadth (B4)
5
52
21
Height (H4)
2
8
6
Chamfer angle (A)
45 Degree
60 Degree
45 Degree
Chamfer length (C)
0.1
0.5
0.3
Fillet radius (F)
0.1
1
0.3
Diameter of Hole (D)
0.1
6
2
Hole depth (H5)
0.2
8
4
Offset dimension (O)
4
4
4
No. of holes in array (Nx and Ny)
50
3000
72
In an embodiment, the polymer employed in making the counter template mold of mold is selected from a group comprising Acrylonitrile butadiene styrene (ABS), Poly lactic acid (PLA), Poly lactic-co-glycolic acid (PLGA), Poly glycolic acid (PGA), Poly vinyl alcohol (PVA), Poly styrene (PS), and other derivatives of these polymers.
In an exemplary embodiment, the preferred polymer in making the counter template mold of mold is Poly lactic acid (PLA).
In an embodiment, the 3D printing technique employed is stereo lithography technique by a 3D printer, 3D Systems ProJet 7000 by 3D Systems, ‘u’ print SE plus or WOL3D ENDER.
In an exemplary embodiment, the 3D printer is WOL3D ENDER.
In an embodiment, the metal employed in making the counter template mold of mold is selected from a group comprising Oil Hardened Non-Shrinking Steel, Stainless-steel and titanium, Stainless steel and copper, Palladium, nickel or palladium-cobalt, the preferred metal being Oil Hardened Non-Shrinking Steel.
In an embodiment, the micromachining technique employed is erosion spark micromachining (ESM).
In another embodiment, the method of preparing a counter template of metal mold by ESM comprises the steps of:
i) making a counter mold of a metal master mold using copper metal; and
ii) using the copper counter mold of step i) as a cutter to cut off the unwanted part from the substrate metal block (stainless-steel block) using erosion spark.
In an embodiment of the present disclosure, the method of making molds can be automated and hence multiple molds may be produced by using the same counter-template. More importantly, automation will decrease cost of production of molds, and eventually TMA block and TMA slides for analysis of nucleotides like DNA, RNA and oligo- and poly- peptides, proteins, fat, carbohydrate and metabolites for their respective analysis. Thus, the present method step of designing a counter template of mold enables making multiple counter molds. Most importantly, the variation among the prepared molds is limited as same counter-template is used. Further, the said method is advantageous as it is simple, economical and time saving.
In an embodiment, the present method aids in making multiple counter templates that may be for one or more-time usage.
In another embodiment, a 3D printed template of polymer material like Poly lactic acid (PLA), or Micromachined template of material like stainless steel makes a sturdy counter template. Thus, as PLA is a long-lasting material, it can be used multiple times for making mold for recipient TMA block. In the same way, micromachined steel template can be used multiple times for making mold for recipient TMA block.
In an embodiment, the present method is suitable for researchers and in the field of pathology.
In an embodiment, the counter template mold obtained by the method described herein has wide range of applications including detection and quantification of nucleotides like DNA, RNA, siRNA, peptides including polypeptides, proteins, fat, carbohydrate and metabolites detection applications.
The present disclosure further relates to a counter template mold of metal or polymer for the preparation of mold of recipient TMA blocks obtained by the method described herein. Said counter template mold is sturdy, cost effective/ economical, durable, crack free with uniform projections, uniform holes, smooth and continuous surface and can be used multiple times. Said counter template mold can be used in wide range of applications including detection and quantification of nucleotides like DNA, RNA, siRNA, peptides including polypeptides, proteins, fat, carbohydrate and metabolites detection applications.
In an embodiment, the counter template mold is sturdy and cost effective/economical.
In an embodiment, the counter template mold is durable with uniform projections, uniform holes.
In a yet another embodiment, the counter template mold is crack free.
In a still another embodiment, the counter template mold has smooth and continuous surface and can be used multiple times.
In an embodiment, the counter template mold can be used in wide range of applications including detection and quantification of nucleotides like DNA, RNA, siRNA, peptides including polypeptides, proteins, fat, carbohydrate and metabolites detection applications.
The present disclosure is further defined in the following examples. It should be understood that these examples indicating exemplary embodiments of the present disclosure are given by way of illustration only and should not be construed to limit the scope of the disclosure. From the above discussion and these examples, one skilled in the art can ascertain the essential characteristics of this disclosure, and without departing from the spirit and scope thereof, can make various changes and modifications of the disclosure to adapt it to various uses and conditions.
EXAMPLES:
EXAMPLE 1: Preparation of a design of counter template mold.
In the present method of preparing a counter template mold for the preparation of mold of empty recipient TMA block, at step a) of the method of the present disclosure, a design of counter template of mold of a recipient TMA block of suitable dimensions is created using computer aided design (CAD) software. The various steps involved in the preparation method of design of counter template of mold in accordance with an embodiment of the present disclosure is represented as a flowchart in Figure 2.
Figure 1 (a-b) shows the design of counter template mold made in CAD software (CATIA V5R19 software) with suitable dimensions in accordance with an embodiment of the present disclosure. The said dimensions are as follows. The counter template mold has a rectangular shape (R1) wherein the length (L1), breadth (B1) and height (H1) are 58 mm, 37 mm and 14 mm respectively. Further, the length (L2), breadth (B2) and height (H2) of the inner rectangle (R2) are 54 mm, 33 mm and 10 mm respectively, the length (L3), breadth (B3) and height (H3) of the inner rectangle (R3) are 42 mm, 23 mm and 2 mm respectively and the length (L4), breadth (B4) and height (H4) of the inner rectangle (R4) are 40 mm, 21 mm and 6 mm respectively. Furthermore, the chamfer angle (A) is 45 degree, chamfer length (C) is 0.3 mm, the fillet radius (F) is 0.3 mm; the diameter of hole (D) is 2 mm; the hole depth (H5) is 4mm; the offset dimension (O) is 4 mm; and the number of holes in the array (Nx-axis and Ny-axis) are 72.
EXAMPLE 2: Preparation of metal or polymer counter template mold
At step b) of the method of the present disclosure, a metal or polymer counter template mold of mold of an empty recipient TMA block is prepared from the CAD design of step a) by using advance techniques like 3D printing or micromachining.
2.1: Metal counter template mold:
To obtain a metal counter template mold of mold of the empty recipient TMA block, advance technique like micromachining is employed.
At step b) of the method of the present disclosure, the output of the CAD design of step a) saved as .igs format is converted into .stp file format for micromachining and provided to a micromachining unit to obtain a metal counter template of mold of a recipient TMA block.
The metal employed is Oil Hardened Non-Shrinking Steel and the micromachining technique, Erosion spark micromachining (ESM) is employed to remove the unwanted part from the steel block/substrate.
The said method of preparing a steel counter template mold by ESM comprises the steps of:
i) making a counter mold of a metal master mold using copper metal; and
ii) using the copper counter mold of step i) as a cutter to cut off the unwanted part from the substrate metal block (steel block) using erosion spark.
Figures 6 and 7 show Micromachining (stage) with the finished product. Figure 8 shows Counter Mold made after micromachining process in accordance with an embodiment of the present disclosure.
2.2: Polymer counter template mold:
To obtain a polymer counter template mold of mold of the empty recipient TMA block, advance technique like 3D printing is employed.
At step b) of the method of the present disclosure, the output of the CAD design of step a) is provided to a 3D printer. The output of the CAD design saved as .igs format is converted into .stl format and then command is given to the 3D printer for printing. G-code file containing instructions is created from .stl file. The 3-D printer then followed this instruction from G-code file to build a counter-mold by putting down successive layers of material (polymer).
Poly lactic acid (PLA) polymer is used and 3D printing is done by employing stereo lithography technique by a 3D printer, WOL3D ENDER.
Figure 3 and 3a shows 3D printing in process in accordance with an embodiment of the present disclosure. Figure 4 and 4a shows 3D printer, WOL3D ENDER in accordance with an embodiment of the present disclosure and Figure 5 shows Counter Mold made after 3D printing
process in accordance with an embodiment of the present disclosure.
Additional embodiments and features of the present disclosure is apparent to one of ordinary skill in art based on the description provided herein. The embodiments herein provide various features and advantageous details thereof in the description. Descriptions of well- known/conventional methods and techniques are omitted so as to not unnecessarily obscure the embodiments herein. The foregoing description of the specific embodiments fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without
departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein. With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity. While considerable emphasis has been placed herein on the particular features of this disclosure, it will be appreciated that various modifications can be made, without departing from the principles of the disclosure. These and other modifications in the nature of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. , Claims:We Claim:
1. A method of preparing a counter template mold of mold used for the preparation of empty recipient block of Tissue microarray (TMA), comprising:
a)
creating a computer aided design (CAD) of counter template of mold of a recipient TMA block of suitable dimensions;
b)
providing the output of the CAD design of step a) to a micromachining unit or a 3D printer to obtain a metal or polymer counter mold of mold of a recipient TMA block; wherein the output of the CAD design of step a) is fed to a micromachining unit to obtain a metal counter template mold of mold of the empty recipient TMA block; or wherein the output of the CAD design of step a) is fed to a 3D printer to obtain a polymer counter template mold of mold of the empty TMA recipient block.
2. The method of preparing a counter template mold as claimed in claim 1, wherein the design of counter template of mold comprises the steps of:
a)
Open modeling software;
b)
Open part modeling tool in the CAD software;
c)
Select a plane for sketching;
d)
Sketch a rectangle (R1) having dimensions (length L1 and breadth B1);
e)
Extrude the rectangle to convert the sketch of the rectangle into a rectangular block wherein the dimension of height is H1;
f)
Draw three rectangles R2, R3 and R4, wherein the dimensions of R2 are (length L2 and breadth B2), dimensions of R3 are (length L3 and breadth B3), dimensions of R4 are (length L4 and breadth B4);
g)
Select two rectangles, R2 and R3, remove material between these two rectangles using Extrude/Cut/Relevant option in the software up to depth H2 to form a rectangular grove and a central rectangular projection;
h)
Select two rectangles, R3 and R4, remove material between these two rectangles, using Extrude/Cut/Relevant option in the software up to depth H3 to form a rectangular step below the central rectangular projection;
i)
Using rectangle R4 remove material up to depth equal to H4;
j)
Add a chamfer at rectangular locations corresponding to R1, R2, R3 and R4, wherein
Chamfer at ‘A’ degrees is preferred but the angle can vary, and the chamfer length
is ‘C’ and wherein the said step is optional, as adding this feature will give a better look to the design;
k)
Add fillet to all the grove edges with Fillet radius ‘F’ wherein the said step is optional as adding this feature will give a better look to the design;
l)
Sketch a circle at the location of the positional hole preferably at one of the corners of the rectangular protrusion wherein the diameter of the hole is ‘D’;
m)
Extrude this circle and remove the material to create a positioning hole, wherein the Depth of the hole is H5;
n)
Add a chamfer or fillet to the positioning hole wherein the said step is optional, addition of a chamfer or fillet will improve ease of positioning, wherein the Chamfer at 45 degrees is preferred but the angle can vary, wherein the chamfer length is ‘C’; or fillet radius is ‘F’;
o)
Sketch a circle at the corner location of the array of holes wherein the diameter of the hole is ‘D’;
p)
Extrude this circle and remove the material to create a hole wherein the Depth of the hole is H5;
q)
Add a chamfer or fillet to this hole wherein Chamfer at 45 degrees is preferred but the angle can vary, wherein the chamfer length is C; Or fillet radius is F;
r)
Create an array of holes (along with the chamfer or fillet) to form the matrix of holes by giving the offset dimension center to center (O) and number of holes along the length (Nx) and width (Ny);
s)
Optionally, the chamfer or fillet at the top edge of each hole can be given after creating the array of holes;
t)
The modeling order of a few steps can be interchanged, for example, steps for positional hole and array of hole can be interchanged; and
u)
Save the CAD file.
3. The method of preparing a counter template mold as claimed in claims 1 or 2, wherein the design of counter template of mold comprises the steps of:
a)
Open CAD software, CATIA V5R19;
b)
Start> Mechanical design> Part design;
c)
Select X-Y plane;
d)
Sketch > Centered rectangle (R1);
e)
Give thickness (H1) to drawn rectangle using option Pad;
f)
Select X-Y plane;
g)
Sketch > Centered rectangle – draw two rectangles (R2 and R3);
h)
Create grove using Pocket option up to depth H2;
i)
Sketch > Centered rectangle – draw two rectangles (R3 and R4);
j)
Create step using Pocket option up to depth H3;
k)
Sketch > Centered rectangle (R4);
l)
Remove material up to depth H4 using option Pocket option;
m)
Add Fillet/Chamfer in the Dress-Up Features toolbar to the six dominant rectangular edges wherein the said step is optional and wherein the Dimensions are- Fillet radius F, chamfer length C, and chamfer angle A.
n)
Create positioning hole using Hole feature in CATIA wherein Hole diameter is D and depth is H5.
o)
Add Fillet/Chamfer in the Dress-Up Features toolbar to the top edge of the positioning hole wherein Dimensions are- Fillet radius F, chamfer length C, and chamfer angle A.
p)
Create the first hole of the array of holes using Hole feature in CATIA. wherein Hole diameter is D and depth is H5.
q)
Create array of holes using Rectangular Pattern feature in CATIA. wherein Offset dimension is (O) and number of holes along the length is (Nx) and width is (Ny);
r)
Add a chamfer or fillet to these holes using Fillet/Chamfer in the Dress-Up Features toolbar.
s)
The modeling order of a few steps can in interchanged, for example, steps for positional hole and array of hole can be interchanged;
t)
Save the file as .CAT Product;
u)
Export the file for printing in required format (e.g *.igs format).
4. The method of preparing a counter template mold as claimed in any one of claims 1 to 3, wherein the design of counter template of mold saved as .igs format in step a) is converted into .stp file format in step b) for micromachining to obtain a metal counter template mold of mold of a TMA recipient block.
5. The method of preparing a counter template mold as claimed in any one of claims 1 to 3, wherein the design of counter template of mold saved as .igs format in step a) is converted into .stl format in step b) for feeding into a 3D printer to obtain a polymer counter template mold of mold of a TMA recipient block.
6. The method of preparing a counter template mold as claimed in any one of claims 1 to 3, wherein the mold template has a rectangular shape (R1); wherein the length (L1) ranges from 2.5 mm to 100 mm, breadth (B1) ranges from 2 mm to 75 mm and height (H1) ranges between 0.5 mm to 30 mm, the preferred length (L1), breadth (B1) and height (H1) being 58 mm, 37 mm and 14 mm respectively, wherein the inner rectangular shape (R2) present inside R1 has length (L2) ranging from 2 mm to 95 mm, breadth (B2) ranging from 1.5 mm to 70 mm and height (H2) ranging between 0.3 mm to 20 mm, the preferred length (L2), breadth(B2) and height (H2) being 54 mm, 33 mm and 10 mm respectively; wherein the inner rectangular shape (R3) present inside R2 has length (L3) ranging from 1.2 mm to 78 mm, breadth (B3) ranging from 0.7 mm to 54 mm and height (H3) ranging between 0.1 mm to 5 mm, the preferred length (L3), breadth (B3) and height (H3) being 42 mm, 23 mm and 2 mm respectively; wherein the inner rectangular shape (R4) present inside R3 has length (L4) ranging from 10 mm to 76 mm, breadth (B4) ranges from5 mm to 52 mm and height (H4) ranges between 2 mm to 8 mm, the preferred length (L4), breadth (B4) and height (H4) being 40 mm, 21 mm and 6 mm respectively; wherein the chamfer angle (A) ranges from 45 to 60 degree, the preferred angle being 45 Degree and chamfer length (C) ranges from 0.1 mm to 0.5 mm, the preferred length being 0.3 mm; wherein the fillet radius (F) ranges from of 0.1 mm to 1mm, the preferred radius being 0.3 mm; wherein the diameter of hole (D) ranges from 0.1 mm and 6 mm, the preferred diameter being 2 mm; wherein the hole depth (H5) ranges from 0.2 mm to 8 mm, the preferred depth being 4 mm; wherein the offset dimension (O) is of 4 mm; and wherein the number of holes in the array (Nx-axis and Ny-axis) are in range of 50 and 3000, the preferred number of holes being 72.
7. The method of preparing a counter template mold as claimed in claim 1, wherein the polymer employed in making the counter template of mold is selected from a group comprising Acrylonitrile butadiene styrene (ABS), Poly lactic acid (PLA), Poly lactic-co-glycolic acid (PLGA), Poly glycolic acid (PGA), Poly vinyl alcohol (PVA), Poly styrene (PS), and other derivatives of these polymers; wherein the 3d printing technique employed is stereo lithography technique by a 3D printer, 3D Systems ProJet 7000 by 3D Systems, ‘u’
print SE plus or WOL3D ENDER.
8. The method of preparing a counter template mold as claimed in claims 1 or 7, wherein the preferred polymer in making the counter template of mold is Poly lactic acid (PLA) and wherein the preferred 3D printer is WOL3D ENDER.
9. The method of preparing a counter template mold as claimed in claim 1, wherein the metal employed in making the counter template of mold is selected from a group comprising Oil Hardened non-shrinking Steel, Stainless-steel and titanium, Stainless steel and copper, Palladium, nickel or palladium-cobalt, the preferred metal being Oil Hardened Non-Shrinking Steel; and wherein the micromachining technique employed is Erosion spark micromachining (ESM).
10. The method of preparing a mold as claimed in claims 1 or 9, wherein the method of preparing a counter template of metal mold by Erosion spark micromachining (ESM) comprises the steps of:
i) making a counter mold of a metal master mold using copper metal; and
ii) using the copper counter mold of step i) as a cutter to cut off the unwanted part from the substrate metal block (stainless-steel block) using erosion spark.
11. A counter template mold of metal or polymer for the preparation of mold of TMA recipient blocks prepared by the method as claimed in claim 1.
12. The counter template mold as claimed in claim 11, wherein the counter mold is sturdy, cost effective/ economical, durable, crack free with uniform projections, uniform holes, smooth and continuous surface and can be used multiple times.
13. The counter template mold as claimed in claims 1 or 11, wherein the counter mold has wide range of applications including detection and quantification of nucleotides like DNA, RNA, siRNA, peptides including polypeptides, proteins, fat, carbohydrate and metabolites detection applications.