Patent ID: 8197029

Claim:
A method for forming a nozzle plate of a fluid ejection device, comprising: etching a first side of a semiconductor layer through a first opening in a first patterned mask to form a tapered feature, wherein the semiconductor layer is part of a multilayer substrate and an etch stop layer is adjacent to the semiconductor layer; and etching the first side of the semiconductor layer to form a straight walled feature, wherein walls of the straight walled feature intersect walls of the tapered feature and the walls of the straight walled feature are perpendicular to a surface of the first side of the semiconductor layer, wherein the tapered feature resides closer to the first side of the semiconductor layer than the straight walled feature does, and the etching to form the tapered feature occurs after the etching to form the straight walled feature, wherein the first opening in the first patterned mask exists before the etching to form the straight walled feature is started, and wherein the method further comprises: before the etchings to form the tapered feature and the straight walled feature are started: depositing a layer of first mask material on the first side of the semiconductor layer and patterning the layer of first mask material to form the first opening in the first patterned mask; depositing a layer of second mask material over the first patterned mask; and creating a second opening in the layer of second mask material to form a second patterned mask, wherein the second opening passes through the first opening.