Patent ID: 7296350

Claim:
A method for fabricating a drop generator ( 30 ) comprising the steps of: a. identifying a non-conductive dimensionally stable structure ( 10 a ) with a shape adapted to define a fluid cavity for the drop generator ( 30 ) for an ink jet printer, wherein the structure comprises a first end ( 12 ), a second end ( 14 ), a first portion ( 16 ) to be formed into a channel ( 17 ) for the drop generator ( 30 ), and a second portion ( 18 ) to be formed into a slot ( 19 ) for transferring fluid from the channel to an orifice plate ( 20 ); b. covering the first end ( 12 ) with a first cap ( 21 ) and covering the second end ( 18 ) with a second cap ( 22 ); c. mounting a conductive base ( 24 a ) to the non-conductive dimensionally stable structure ( 10 a ) to surround at least part of the second portion ( 18 ); d. electroforming metal on the conductive base ( 24 a ) to encapsulate the non-conductive dimensionally stable structure ( 10 a ) between the first cap ( 21 ) and the second cap ( 22 ) to a thickness at least equivalent to a desired outer dimension, thereby forming an encapsulated structure ( 29 ); e. removing the first cap ( 21 ) and the second cap ( 22 ) from the encapsulated structure ( 29 ); and f. removing the non-conductive dimensionally stable structure ( 10 a ) to form the drop generator ( 30 ) with the channel ( 17 ) adapted to receive fluid and the slot ( 19 ) adapted to communicate fluid from the channel ( 17 ) to the orifice plate ( 20 ).