Patent ID: 7247248

Claim:
A method of. . . (a) depositing a masking layer onto a first layer of doped silicon so that some square or rectangular areas of the first layer of doped silicon are not covered by the masking layer, (b) etching pyramidal apertures in the first layer of doped silicon, (c) removing the masking layer, (d) depositing a second layer of doped silicon onto the first layer of doped silicon, the second layer of doped silicon being oppositely doped to the first layer of doped silicon, (e) etching away the first layer of doped silicon, (f) before the first layer of doped silicon is etched in step (e) performing an anisotropic wet etch on the second layer of silicon to provide at least one raised area, (g) fusion bonding a third layer of silicon over the raised area to form at least one cavity between the second layer and the third layer, (h) following the step of etching away the first layer of doped silicon in step (e) depositing a second masking layer over the second layer of silicon on the side previously in contact with the first layer of silicon, (i) patterning the second masking layer to include an area of no masking at one side of a tip, (j) performing a release etch to remove silicon above the cavity not covered by the second masking layer, and (k) removing the second masking layer.