In this paper, a new replication technique for a real 3D microstructure was introduced, in which a master pattern was made of photo-curable epoxy using a microstereolithography technology, and then it was transferred onto an epoxy-copper particle composite. A helical gear was selected as one of the real 3D microstructure for this study, and it was replicated from a pure epoxy to an epoxy composite. In addition, the transferability of the microreplication process was evaluated, and the properties of the epoxy composite were compared to that of the pure epoxy, including hardness, wear-resistance and thermal conductivity.
