Patent ID: 8736645

Claim:
A printhead fabrication method comprising: providing a spacer layer over a plurality of bottom electrodes of a printhead; providing a plurality of top electrodes of the printhead over the spacer layer and the bottom electrodes; aligning a plurality of printhead features of the spacer layer with a plurality of printhead features of the top electrodes and the bottom electrodes; and bonding the spacer layer with the top electrodes and the bottom electrodes with the printhead features of the spacer layer aligned with the printhead features of the top electrodes and the bottom electrodes, wherein the bonding includes: first bonding, while maintaining the alignment of the spacer layer relative to the top electrodes and the bottom electrodes, a plurality of different portions of the spacer layer with respect to the top and bottom electrodes at a plurality of different locations to form localized bonds without introducing lateral forces on the spacer layer during the first bonding; and after the first bonding, second bonding substantially an entirety of the spacer layer with the top and bottom electrodes while maintaining the localized bonds.