Patent ID: 6841339

Claim:
A method for making a silicon micro-mold, comprising the steps of: providing a silicon substrate, said substrate having top and bottom surfaces and a thickness therebetween; forming an electrically conductive layer onto said bottom surface; forming a photoresist layer onto said top surface; aligning an image patterning mask onto said photoresist layer, wherein said mask having closed portions for blocking light and open portions for allowing light to pass through; directing a source of broadband light onto said mask, thereby exposing portions of said photoresist layer lying beneath said mask open portions; removing said mask; developing said photoresist layer so that a portion of said photoresist is removed to expose areas of said silicon substrate, and a portion of said photoresist remains as a protective etch barrier; anisotropically etching said exposed areas of said silicon substrate through said substrate thickness to said electrically conductive layer, thereby providing a plurality of etched trenches comprising substantially vertical walls surfaces and floor surfaces comprising said electrically conductive layer; removing said remaining photoresist; and oxidizing the surfaces of the silicon substrate after the step of removing said photoresist.