Patent ID: 7273693

Claim:
A method for making a micro mirror device, the method comprising: forming a mirror actuator; depositing a first sacrificial oxide layer above the mirror actuator; depositing a hinged member at least partially on the first sacrificial oxide layer, wherein the hinged member comprises: one or more hinges configured to allow the hinged member to be displaced during actuation; and a rigid portion distal to the one or more hinges not subject to deformation during actuation; depositing a second sacrificial oxide layer at least partially above the hinged member; forming voids in the second sacrificial oxide layer, the voids extend from the hinged member to an upper surface of the second sacrificial oxide layer; forming metal vias in the voids that extend from the hinged member to the upper surface of the second sacrificial oxide layer, wherein the metal vias connect to the rigid portion of the hinged member distal to the one or more hinges; forming a mirror plate on the upper surface of the sacrificial layer, to secure the mirror plate to the metal vias, thereby establishing a connection between the mirror plate and the rigid portion of the hinged member, wherein the connection is configured to require the rigid portion and the mirror plate to move in a parallel relationship during actuation that resists deformation of the mirror plate; and removing the first sacrificial oxide layer and the second sacrificial oxide layer to leave behind the micro mirror device formed including the hinged member, the metal vias, and the mirror plate.