Okay, this is more of an engineering tactic question perhaps, but any insight into any possible process will be very, very appreciated. So I'm mixing a powder with epoxy, making a pasty, fluid semi-solid and layering it on a plastic layer. I need alternating layers of plastic (200 microns) and powder+epoxy mix (12 microns). Now 12 microns is too thin, and I'm not sure how I'd go about accomplishing this. The tolerance on this layer is +- 5 microns (maximum). How do I go about making such thin a layer? I have been able to accomplish 35 microns so far, nothing lower, by taping a 35-micron thick tape to the plastic surface, and having that guide my paintbrush, and then sandwich another plastic layer on top. The area of these surfaces can be anything between a 35mm-diamteter circle to a 5" x 5" square sheet. Thanks!
Something like sputtering: Epoxy has solvents, and would spoil a high vacuum. So freeze a sample of epoxy/powder mix, perhaps with LN2. Put it in a high vacuum, and heat a spot on the surface to sputter. Perhaps you might use a laser or electron beam.