Patent ID: 7531382

Claim:
A method of creating a patterned device comprising the steps of: a) selecting a substrate having a top surface that is resistant to removal by at least one removal agent; b) depositing a mask layer having a top surface that is resistant to removal by at least one removal agent on the top surface of the substrate; c) forming a first step on the mask layer, the first step having a top surface, wherein the first step and the mask layer have a common resistance to removal by at least one agent; d) depositing a sacrificial layer having a top surface along the first step and the mask layer, the sacrificial layer being removable by an agent to which the first step and the mask layer share a common resistance; e) depositing a blocking layer on the sacrificial layer that is resistant to removal by an agent to which the mask layer and first step share a common resistance; f) removing a user-definable portion of the blocking layer, wherein a portion of the blocking layer remains such that no gap exists between the blocking layer and the sacrificial layer and the remaining blocking layer is adhered to the mask layer, the thickness of the remaining blocking layer being user-definable; g) removing a user-definable portion of the sacrificial layer such that a gap is created between the blocking layer adhered to the mask layer and the first step, wherein at least a portion of the sacrificial layer remains such that the blocking layer adhered to the mask layer remains; h) etching the mask layer beneath the gap created between the remaining blocking layer and first step such that a gap exists in the mask layer; and i) processing the substrate through the gap in the mask layer.