Patent ID: 7372616

Claim:
A process for forming a multilayer microdevice, comprising: (a) forming a layer comprising at least two materials on a substrate that may include one or more previously deposited layers, each comprising at least two materials, wherein one of the at least two materials is a structural material and another of the at least two materials is a sacrificial material; (b) repeating the forming operation of “(a)” one or more times to form at least one subsequent layer, comprising at least two materials on at least one previously formed layer to build up a three-dimensional structure from a plurality layers; wherein the forming of at least a plurity of layers, comprises: (1) supplying a substrate; (2) supplying a mask on a surface of the substrate having a desired pattern of openings through which a first material of the at least two materials can be effectively deposited or etched to yield a desired pattern of the first material; (3) depositing the first material within the openings or etching the first material from the openings; (4) removing the mask; (5) depositing a second material of the at least two materials to fill the void in the deposited material; and (6) planarizing the deposited first and second materials to provide a planarized layer; and (c) after formation of the plurality of layers removing the sacrificial material from the deposited structural material, to reveal the three-dimensional structure, wherein the microdevice includes a 3D tilt mirror.