Patent ID: 7271022

Claim:
A process for forming a micromechanical structure comprising: providing a plating base on a surface of a substrate; forming a first photoresist layer on the plating base; exposing the first photoresist layer to a first pattern of radiation to render the first photoresist layer dissolvable in a first pattern; removing the dissolvable photoresist of the first photoresist layer; electroplating a layer of a primary metal onto the plating base in the area where the first photoresist layer has been removed; removing the remainder of the first photoresist layer; forming a second photoresist layer over the plating base and the layer of primary metal; exposing the second photoresist layer to a second pattern of radiation to render the second photoresist layer dissolvable in a second pattern, the second pattern being formed such that an area surrounding the primary metal is dissolved, wherein the area is less than the entirety of the substrate; removing the dissolvable photoresist of the second photoresist layer; electroplating an amount of a secondary metal in the area where the second photoresist layer has been removed; removing the remainder of the photoresist of the second photoresist layer; electroplating an amount of a third metal over substantially the entire length of the substrate; machining the third metal, the secondary metal, and the primary metal down to a substantially flat surface corresponding to a desired height of the layer of primary metal; and etching away the remainder of the secondary and third metals.