Patent ID: 7618525
Filing Date: 2009-11-17
Classification: B33Y,B81C,C25D,H01L,H05K,Y10T

Abstract:
1. A method for fabricating a multi-layer, multi-component three-dimensional structure, comprising: I. forming a first layer on a substrate comprising depositing at least one sacrificial material and depositing 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; II. forming additional layers adjacent to and adhered to previously formed layers, wherein the formation of each layer comprises depositing at least one sacrificial material and depositing at least one structural material and wherein the deposited sacrificial material and the deposited structural material for each additional layer are planarized to have a common height to set a boundary level for each additional layer, wherein the components of the structure are pre-aligned but unassembled prior to etching of the at least one sacrificial material and wherein at least one of the components includes at least one retention element for retaining the plurality of components in an assembled state relative to one another after moving into the assembled state; and III. after formation of the additional layers, etching at least one sacrificial material from a plurality of layers to reveal the pre-aligned components of the three-dimensional structure and moving the pre-aligned components relative to one another, along a path that is defined by the alignment of the pre-aligned components, into the assembled state such that the at least one retention element is engaged to retain the plurality of components in the assembled state.