Patent ID: 7262900

Claim:
A process for forming a metal hinge post structure over an electrically conductive electrode comprising the steps of: forming a patterned spacer layer having a top surface on said electrically conductive electrode, said patterned spacer layer defining at least one hinge post aperture extending from said top surface through said spacer layer to said electrically conductive electrode; forming a metal layer over said spacer layer; forming an oxide layer over said metal layer; depositing a protective layer over said oxide layer, said protective layer deposited to a first thickness over said top surface of said spacer layer and to a second thickness in said at least one hinge post aperture, said second thickness greater than said first thickness; etching said protective layer to expose said oxide layer, such that only a layer of said protective material remains at the bottom of said at least one hinge post aperture; anisotropically etching said oxide layer such that a cup-shaped layer of oxide remains in said at least one hinge post aperture; and cleaning said metal layer and said at least one hinge post aperture.