A method for producing a porous aluminum foil of the present invention is characterized in that a porous aluminum film is formed on a surface of a substrate by electrolysis using a plating solution containing at least (1) a dialkyl sulfone, (2) an aluminum halide, and (3) a nitrogen-containing compound, and having a water content of 100 to 2000 ppm, and then the film is separated from the substrate. The nitrogen-containing compound is preferably at least one selected from the group consisting of an ammonium halide, a hydrogen halide salt of a primary amine, a hydrogen halide salt of a secondary amine, a hydrogen halide salt of a tertiary amine, and a quaternary ammonium salt represented by the general formula: R.sup.1R.sup.2R.sup.3R.sup.4N.X (R.sup.1 to R.sup.4 independently represent an alkyl group and are the same as or different from one another, and X represents a counteranion for the quaternary ammonium cation).

A method for manufacturing a composite part of polymer and metal utilizes a mold having a plurality of mold parts and forming a layer of metal on at least one inner or cavity-facing surface of the mold. Thereafter the mold parts are assembled to one another to form a mold cavity defined in part by the layer of metal. The mold cavity is then filled with resin material so that the resin material is in contact with the layer of metal. A curing or hardening of the resin material in the mold cavity is followed by an opening of the mold and the removal of a composite part having a metal shell or outer layer and a polymeric backing or inner layer.

A method of producing graphene sheets directly from graphite mineral (graphite rock) powder, comprising: (a) forming an intercalated graphite compound by an electrochemical intercalation procedure conducted in an intercalation reactor, containing (i) a liquid solution electrolyte comprising an intercalating agent and a graphene plane-wetting agent dissolved therein; (ii) a working electrode that contains the graphite material powder as an active material; and (iii) a counter-electrode, and wherein a current is imposed upon the working electrode and counter electrode at a current density sufficient for effecting electrochemical intercalation of the intercalating agent and/or wetting agent into interlayer spacing, wherein the wetting agent is selected from melamine, ammonium sulfate, sodium dodecyl sulfate, Na(ethylenediamine), tetraalkyammonium, ammonia, carbamide, hexamethylenetetramine, organic amine, poly(sodium-4-styrene sulfonate), or a combination thereof; and (b) exfoliating and separating the intercalated graphite compound using ultrasonication, thermal shock exposure, and/or a mechanical shearing treatment to produce graphene sheets.

Embodiments are directed to forming reentrant multi-layer micro-scale or millimeter scale three dimensional structures, parts, components, or devices where each layer is formed from a plurality of deposited materials and more specifically where each layer is formed from at least one metal structural material and at least one organic sacrificial material (e.g. polymer) that are co-planarized and a portion of the sacrificial material located on a plurality of layers is removed after formation of the plurality of layers via one or more plasma etching operations or one or more neutral radical etching operations.

Embodiments are directed to forming reentrant multi-layer micro-scale or millimeter scale three dimensional structures, parts, components, or devices where each layer is formed from a plurality of deposited materials and more specifically where each layer is formed from at least one metal structural material and at least one organic sacrificial material (e.g. polymer) that are co-planarized and a portion of the sacrificial material located on a plurality of layers is removed after formation of the plurality of layers via one or more plasma etching operations or one or more neutral radical etching operations.

A titanium foil or a titanium sheet is produced by electrodeposition from molten salt using constant current pulse, the method comprising: forming an electrodeposited titanium film on a surface of a cathode electrode made of glassy carbon, graphite, Mo, and Ni, and separating thereafter the electrodeposited titanium film from the cathode electrode by performing one or both of applying an external force to the electrodeposited titanium film and removing the cathode electrode. This enables the electrodeposited titanium film electrodeposited on the cathode electrode to be peeled from the cathode electrode simply and at low cost.

A titanium foil or a titanium sheet is produced by electrodeposition from molten salt using constant current pulse, the method comprising: forming an electrodeposited titanium film on a surface of a cathode electrode made of glassy carbon, graphite, Mo, and Ni, and separating thereafter the electrodeposited titanium film from the cathode electrode by performing one or both of applying an external force to the electrodeposited titanium film and removing the cathode electrode. This enables the electrodeposited titanium film electrodeposited on the cathode electrode to be peeled from the cathode electrode simply and at low cost.

A method of manufacturing a metal mask includes providing a growth substrate with a conductive surface. Then, a cover pattern is formed on the conductive surface, which has at least one opening and an insulated surface touching the conductive surface. Next, using the cover pattern as a mask, a first electroforming is performed to form a mold part on the conductive surface. The mold part fills the opening and has a conductive pattern surface touching the conductive surface. The conductive pattern surface is flush with the insulated surface. After the first electroforming, the growth substrate is removed, while the cover pattern and the mold part are reserved. After removing the growth substrate, a second electroforming is performed to the conductive pattern surface of the mold part to form a metal pattern. Afterwards, the mold part and the cover pattern are removed from the metal pattern.

A method of manufacturing a metal mask includes providing a growth substrate with a conductive surface. Then, a cover pattern is formed on the conductive surface, which has at least one opening and an insulated surface touching the conductive surface. Next, using the cover pattern as a mask, a first electroforming is performed to form a mold part on the conductive surface. The mold part fills the opening and has a conductive pattern surface touching the conductive surface. The conductive pattern surface is flush with the insulated surface. After the first electroforming, the growth substrate is removed, while the cover pattern and the mold part are reserved. After removing the growth substrate, a second electroforming is performed to the conductive pattern surface of the mold part to form a metal pattern. Afterwards, the mold part and the cover pattern are removed from the metal pattern.

A hydrogel is formed by a reaction which is induced, in an electrolytic solution, by an electrode product electrochemically generated by electrodes installed in the electrolytic solution. An apparatus including an electrolytic tank with a bottom surface on which a two-dimensional array of working electrodes is provided and a counter electrode installed in the electrolytic tank is prepared. An electrolytic solution containing a dissolved substance that causes electrolytic deposition of a hydrogel is housed in the electrolytic tank. By applying a predetermined voltage to one or more selected working electrodes of the two-dimensional array, a hydrogel with a two-dimensional pattern corresponding to the arrangement of the selected working electrodes is formed.