Patent ID: 7615479

Claim:
A method comprising: forming a population of recessed regions on a substrate; and depositing a population of functional blocks into said population of recessed regions; each of said functional blocks is deposited in one of said recessed regions, a substantial amount of said population of functional blocks are recessed below a top surface of said substrate, wherein said substantial amount is defined by any one of less than 10% of said population of functional blocks protrudes above said top surface of said substrate, or more than 90% of said population of functional blocks are recessed below said top surface of said substrate, wherein said population of recessed regions are formed using a step-and-repeat process in which one area of said substrate is formed with said population of recessed regions at a time and wherein forming said population of recessed regions on said substrate further comprising: forming a master mold, said master mold comprising silicon wafer with recessed regions similar in shape to said recessed regions to be formed on said substrate; forming a male copy mold from said master mold; forming a female copy mold from said male copy mold; forming a stamper copy mold from said female copy mold; and using said stamper copy mold to form each of said population of recessed regions; wherein each of said master mold, said male copy mold, said female copy mold, and said stamper copy mold comprises feature dimensions provided for each of said population of recessed regions, said feature dimensions for each of said population of recessed regions are about 0.5-1.0% larger than a desired corresponding feature of each of said population of recessed regions.