Patent ID: 7531216

Claim:
A method for deposition a material on a substrate using a shadow mask comprising: (a) providing a shadow mask having a first layer ( 110 ) with a first aperture ( 114 ) therethrough and a second layer ( 112 ) with a second aperture ( 122 ) therethrough, the first and second layers joined together with the first aperture ( 114 ) and the second aperture ( 122 ) offset to define a third aperture ( 130 ) through the first and second layers ( 110 and 112 ), wherein when viewed in a direction normal to the first and second layers ( 110 and 122 ), the third aperture ( 130 ) is smaller than the first aperture ( 114 ) and the third aperture ( 130 ) is smaller than the second aperture ( 122 ); (b) positioning the shadow mask in a vacuum vessel ( 410 ) between a material deposition source ( 412 ) and a substrate ( 414 ); and (c) depositing material from the material deposition source ( 412 ) onto the substrate ( 414 ) via the third aperture ( 130 ) in the presence of a vacuum in the vacuum vessel ( 410 ).