Patent ID: 8702956

Claim:
A fabrication process for forming a multi-layer three-dimensional structure from a first layer formed on and adhered to a substrate and from at least one successive layer with each successive layer formed on and adhered to a planarized surface of a last formed layer and wherein each layer includes a plurality of planarized deposited materials, comprising: (a) forming and adhering a layer on a substrate and forming and adhering a layer to a previously formed layer, wherein a given layer comprises desired patterns of at least two deposited materials, wherein one or more contact pads exist on the substrate or on a previously formed layer; (b) subjecting the at least two deposited materials of the given layer to a planarization operation without subjecting the one or more contact pads to planarization, comprising: (i) mounting the substrate to a fixture in a fly cutting machine; (ii) while the substrate is mounted to the fixture, subjecting the at least two deposited materials to a rotating cutting tool to planarize a surface of the at least two deposited materials for the given layer and to bring the height of the at least two deposited materials for the given layer to a reduced level; (c) after the planarization operation, locating a measurement device in contact with the one or more contact pads; (d) after the planarization operation, locating the measurement device in contact with one or more points on at least one of the at least two deposited materials for the given layer that were subject to the planarization operation; (e) extracting data from the measurement device concerning a measured height of planarized material of at least one point relative to a desired reference point or plane based on the one or more contact pads; (f) comparing the measured height of the at least two planarized materials for the given layer to a desired height for the given layer; (g) if the measured and desired heights are not within a desired tolerance, repeating operations (b)-(f) until the measured and desired heights are within the desired tolerance; (h) repeating the forming and adhering of a layer to a previously formed layer of operation (a) one or more times to form the multi-layer three-dimensional structure from a plurality of adhered layers.