Patent ID: 6859998

Claim:
A method of fabricating an article comprising a projection extending outwardly from a substrate, comprising the steps of forming an overlying structure on the substrate, the overlying structure having an edge thereon; wherein the step of forming the overlying structure includes the steps of depositing a hard-baked resist layer overlying the substrate, depositing a hard mask layer overlying the hard-baked resist layer, depositing an imaging resist layer overlying the hard mask layer, removing a portion of the imaging resist layer to form a step in the imaging resist layer, the hard mask layer being exposed in an area where the imaging resist layer is removed, and removing portions of the hard mask and the hard-baked resist layer that underlie the step in the imaging resist layer; depositing a replication layer lying on the edge; depositing a filler onto the edge and the substrate, so that the filler, the replication layer, and the overlying structure in combination comprise a continuous layer on the substrate, the continuous layer having a free surface with a side of the replication layer exposed at the free surface; selectively removing at least a portion of the replication layer from the free surface inwardly toward the substrate, to form a defined cavity; and depositing a projection material into the defined cavity to form the projection.