Patent ID: 7264984
Filing Date: 2007-09-04
Classification: B81C

Abstract:
1. A process for forming a micromechanical structure comprising: providing a plating base on a surface of a substrate; forming a first photoresist layer on the plating base; exposing the first photoresist layer to a first pattern of radiation to render the first photoresist layer dissolvable in a first pattern; removing the dissolvable photoresist of the first photoresist layer; electroplating a layer of primary metal onto the plating base in the area where the first photoresist layer has been removed; removing the remainder of the first photoresist layer; forming a second photoresist layer over the plating base and the layer of primary metal; exposing the second photoresist layer to a second pattern of radiation to render the second photoresist layer dissolvable in a second pattern, the second pattern being formed such that an area surrounding the primary metal is dissolved, wherein the area is less than the entirety of the substrate; removing the dissolvable photoresist of the second photoresist layer; electroplating an amount of secondary metal in the area where the second photoresist layer has been removed; machining the exposed surface of the secondary metal down to a substantially flat surface corresponding to a desired height of the layer of primary metal; removing the remainder of the photoresist of the second photoresist layer; and etching away the remainder of the secondary metal.