Patent ID: 8613846

Claim:
A fabrication process for forming a multi-layer three-dimensional structure, comprising: (a) forming a first layer comprising at least one structural material and at least one sacrificial material; (b) forming at least one additional layer from at least one structural material and at least one sacrificial material wherein the at least one additional layer is formed on and adhered to a previously formed layer, and wherein the first layer and the at least one additional layer together form a multi-layer three-dimensional structure; and (c) after formation of a plurality of layers, separating at least a portion of the at least one sacrificial material forming a portion of the plurality of layers from the at least one structural material forming another portion of the plurality of layers, wherein a given one of the layers comprises at least one sacrificial material and at least two structural materials, wherein the at least two structural materials comprise a core structural material located at a lower boundary surface of the given layer but not at an upper boundary surface of the given layer and a shell structural material bounding the sides of the core material and providing a cap located above the core structural material and below the upper boundary surface of the given layer such that the shell material bounds the top of the core structural material forming part of the given layer, wherein the core structural material and the shell structural material are different, wherein the lower boundary surface of the given layer is located on an upper boundary surface of a previously formed layer, and wherein at least one of the at least one structural material and the at least one sacrificial material is electrodeposited.