Patent ID: 8512578

Claim:
A method for simultaneously forming a plurality of three-dimensional structures, comprising: (A) forming a plurality of successively formed layers, wherein each successive layer comprises at least two materials and is formed on and adhered to a previously formed layer, one of the at least two materials is a structural material and the other of the at least two materials is a sacrificial material, and wherein each successive layer defines a successive cross-section of a plurality of the three-dimensional structures, and wherein the forming of each of the plurality of successive layers comprises: (i) depositing a first of the at least two materials; (ii) depositing a second of the at least two materials; (iii) planarizing the first and second materials to set a boundary level for the layer; and (B) during or after formation of the plurality of successively formed layers, locating at least one etching barrier to at least partially shield sacrificial material around a portion of the three-dimensional structures from attack by an etchant while the etchant removes sacrificial material from multiple layers around at least another portion of the three-dimensional structures; (C) after locating the barrier and after forming the plurality of successive layers, etching away a portion of the sacrificial material from multiple layers of the structural material to reveal a portion of the three-dimensional structures, (D) after said etching away, removing the barrier; (E) after removing the barrier, etching away another portion of the sacrificial material from multiple layers of the structural material to reveal at least another portion of the three-dimensional structures.