Patent ID: 7981269

Claim:
An electroplating method for fabricating a multi-layer three-dimensional structure, comprising: (i) forming a first layer comprising depositing a first structural material and a first sacrificial material and planarizing the deposited first structural material and first sacrificial material to set a boundary level of the first layer; (ii) forming additional layers with an initial additional layer formed on and adhered to the first layer and with subsequent additional layers formed on and adhered to previously formed additional layers, wherein the forming of each additional layer comprises depositing an additional structural material and depositing an additional sacrificial material and planarizing the deposited additional structural material and additional sacrificial material to set a boundary level for each additional layer; wherein the depositing of a material selected from the group consisting of the additional sacrificial material and the additional structural material for a given one of the additional layers comprises: a) depositing a first portion of the selected material for the given layer using a first patterned mask; and b) depositing a second portion of the selected material for the given layer using a second patterned mask, which is different from the first patterned mask; (iii) removing at least a portion of the sacrificial material deposited on a plurality of layers after formation of the additional layers to at least partially release the three-dimensional structure from the sacrificial material, wherein at least a portion of the depositing steps are electroplating steps.