Patent ID: 6948245

Claim:
A method of manufacturing a worm gear system, said system including a worm gear having an outer surface, and a base plate having a top surface, wherein said gear has an axis of rotation that is horizontal with respect to said top surface of said base plate; said system having a clearance portion between said gear and said base plate so that said gear can be rotated, said clearance portion having an outer surface defining said top surface of said base plate and an inner surface defining said outer surface of said gear; the method comprising the steps of: providing a first material for forming said base plate; applying a first photosensitive agent onto said base plate upper surface; applying an exposure value control method (EVCM) to said first photosensitive agent for forming a first shape defining said bottom surface of said clearance portion; transfer etching said first shape onto said top surface of said base plate, wherein said first photosensitive agent is used as a mask; depositing a second material for forming said clearance portion, said second material being different from said base plate, said second material being deposited after completing said transfer etching method; removing excess second material, wherein said excess includes material that is not required for forming said clearance portion; applying a second photosensitive agent to said base plate upper surface; applying an EVCM to said second photosensitive agent for forming a second shape defining said inner surface of said clearance portion; transfer etching said second shape onto said second material, wherein said second photosensitive agent is used as a mask; depositing a third material for forming said gear onto said base plate; applying a third photosensitive agent to an upper surface of said deposited gear material; applying an EVCM to said third photosensitive agent for forming a third shape defining an upper half of said gear; transfer etching said third shape onto said gear material, wherein said third photosensitive agent is used as a mask; and removing any excess said third material from said clearance portion.