Provided are a method and system for increasing etch rate and etch selectivity of a masking layer on a substrate in an etch treatment system, the etch treatment system configured for single substrate processing. The method comprises placing the substrate into the etch processing chamber, the substrate containing the masking layer and a layer of silicon or silicon oxide, obtaining a supply of steam water vapor mixture at elevated pressure, obtaining a supply of treatment liquid for selectively etching the masking layer over the silicon or silicon oxide at a selectivity ratio, combining the treatment liquid and the steam water vapor mixture, and injecting the combined treatment liquid and the steam water vapor mixture into the etch processing chamber. The flow of the combined treatment liquid and the steam water vapor mixture is controlled to maintain a target etch rate and a target etch selectivity ratio of the masking layer to the layer of silicon or silicon oxide.

Various flexible heat sealable decorative articles and methods of making the same are described. The flexible heat sealable decorative articles are lightweight and can be combined with other decorative elements, such as metalized films. Various decorative are mixed or combined with one another to form highly attractive flexible heat sealable decorative articles.

Systems, methods, and devices for producing appliances for expansion of the arch of a patient are provided. An arch expanding appliance comprises a force generating portion to apply an arch expansion force and a retention portion to hold the force generating portion on the teeth. The retention portion comprises a flexible portion and a stiff portion. The force generating portion applies a force to move teeth associated with the flexible portion, while the stiff portion resists movement of its associated teeth. The orthodontic appliances can be designed according to the specifications provided herein and manufactured using direct fabrication methods.

In some embodiments, a method may include selectively applying a mask to a first surface of a substrate. The mask may include one or more components defining a selected pattern and having a non-uniform density. The method may further include etching the first surface of the substrate based on the mask and selectively processing the first surface of the substrate to produce a multi-dimensional artwork.

A method for making a conductive film includes the steps of: depositing a conductive metal film on a substrate to form a metal-coated substrate; depositing a fiber pattern on the conductive metal film of the metal-coated substrate to form a masked substrate, the fiber pattern defining protected metal and exposed metal of the conductive metal film; removing the exposed metal from the conductive metal film of the masked substrate to form a protected conductive film; and removing the fiber pattern from the protected conductive film to expose the protected metal and provide a metal pattern on the substrate. An annealing step con be employed after depositing the fiber pattern to increase the surface area of contact between the fiber pattern and the conductive metal film.

A method for forming a cutting tool includes masking a metal base with one or more masks, the one or more masks including at least one variable permeability mask, and chemically etching the masked metal base to form a blade of the cutting tool.

A mesh spray erosion assembly includes a spray board having a length, a width, and a material thickness, a tile blank having a length, a width, and a material thickness supported on one side of the spray board, a mesh frame having a length and width greater than that of the tile blank, and a material thickness equal to or less than that of the tile blank, the mesh frame centered over the tile blank and mounted to the spray board, and a mesh screen having a length and a width, the mesh screen centered over the mesh frame and mounted thereon, the mesh screen including non-masked portions and masked portions, characterized in that a user may apply a pressurized liquid spray through the non-masked portions of the mesh screen against the surface of the tile blank eroding material from the surface thereof according to artist design.

A mesh spray erosion assembly includes a spray board having a length, a width, and a material thickness, a tile blank having a length, a width, and a material thickness supported on one side of the spray board, a mesh frame having a length and width greater than that of the tile blank, and a material thickness equal to or less than that of the tile blank, the mesh frame centered over the tile blank and mounted to the spray board, and a mesh screen having a length and a width, the mesh screen centered over the mesh frame and mounted thereon, the mesh screen including non-masked portions and masked portions, characterized in that a user may apply a pressurized liquid spray through the non-masked portions of the mesh screen against the surface of the tile blank eroding material from the surface thereof according to artist design.

A pattern forming method including: (a) forming a porous layer above an etching target layer; (b) forming an organic material with a transferred pattern on the porous layer; (c) forming, by use of the transferred pattern, a processed pattern in a transfer oxide film that is more resistant to etching than the porous layer; and (d) transferring the processed pattern to the etching target layer by use of the transfer oxide film as a mask.

A veneer for a wall-mounted keypad may include indicia that are laser cut therethrough and that are representative of functions that may be performed by the keypad. The veneer may include a recess that extends into an inner surface of the veneer, proximate to the indicia. The recess may be shaped such that a perceived aesthetic of an outer surface of the veneer is preserved during formation of the indicia. The recess may for example have an organic shape defined by a curved outer perimeter that does not define any corners.