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The application of microtechnology to traditional mechanical industries is limited owing to the lack of suitable micropatterning technology for durable materials including metal. In this research, a glassy carbon (GC) micromold was applied for the direct metal forming (DMF) of a microstructure on an aluminum (Al) substrate. The GC mold with microdome cavities was prepared by carbonization of a furan precursor, which was replicated from the thermal reflow photoresist master pattern. A microdome array with a diameter of 8.4 μm, a height of ~0.74 μm, and a pitch of 9.9 μm was successfully fabricated on an Al substrate by using DMF at a forming temperature of 645 °C and an applied pressure of 2 MPa. As a practical application of the proposed DMF process, the enhanced boiling heat transfer characteristics of the DMF microdome Al substrate were analyzed. The DMF microdome Al substrate showed 20.4 ± 2.6% higher critical heat flux and 34.1 ± 5.3% higher heat transfer coefficient than those of a bare Al substrate.

Direct Metal Forming of a Microdome Structure with a Glassy Carbon Mold for Enhanced Boiling Heat Transfer