Patent ID: 7998331
Filing Date: 2011-08-16
Classification: B33Y,B81C,C25D,H01L,H05K,Y10T

Abstract:
1. A method for fabricating a multi-layer three-dimensional structure, comprising: I. forming a first layer on a substrate comprising deposition of at least one sacrificial material and deposition of at least one structural material wherein the deposited sacrificial material and the deposited structural material are planarized to have a common height to set a boundary level for the first layer, and wherein the sacrificial material is etchable with a selected etchant and the structural material is not substantially etchable with the selected etchant; II. forming additional layers adjacent to and adhered to previously formed layers, wherein the formation of each additional layer comprises deposition of at least one additional sacrificial material and deposition of at least one additional structural material and wherein the additional sacrificial material and the additional structural material for each additional layer are planarized to have a common height to set a boundary level for each additional layer; and III. after formation of the additional layers, exposing the combination of the at least one structural material and the at least one sacrificial material to the selected etchant to cause etching of the at least one sacrificial material from a plurality of layers to reveal the components of the three-dimensional structure, wherein exposed portions of the at least one sacrificial material are removed subject to removal by the selected etchant while the exposed portions of the at least one structural material are not removed by the selected etchant, wherein during formation of the plurality of layers, a portion of the at least one sacrificial material becomes encapsulated within a shell of the at least one structural material and becomes a permanent part of the structure, and wherein the deposition of the sacrificial material and the structural material comprises electrodeposition.