Patent ID: 6938310

Claim:
A method of making a multi-layer micro-electromechanical electrostatic actuator for producing drop-on-demand liquid emission devices, said method comprising: on a substrate having a top surface of a first dielectric material, forming an electrically isolated, planar mandrel surrounded by sacrificial material on at least the surfaces of the mandrel not opposing the substrate; providing a lens at a position opposed to the substrate and located over the mandrel; removing, by etching to the substrate, portions of the lens and sacrificial material in at least one region removed from the mandrel by portions of the sacrificial material; forming a subsequent layer of dielectric material on the surfaces above the mandrel and lens opposed to the substrate and within the etched portions of the lens and sacrificial material; removing portions of sacrificial material and portions of the lens so as to form cavities above and below the mandrel which are connected together within the etched portions of the lens and sacrificial material; forming an electrode layer upon the top of the layer of dielectric material; and removing a portion of the substrate material to form a second electrode layer, whereby the first electrode layer and the second electrode layer are free to move together relative to the mandrel and the first electrode layer and the mandrel are electrically isolated from the substrate.