Patent ID: 7501228

Claim:
A method for fabricating an orifice plate with a high density array of nozzles, wherein the method comprises the steps of a. disposing a first photoresist layer ( 10 ) on a glass ( 12 ) with a metalized layer ( 14 ) forming a photomask blank ( 16 ); b. patterning the photomask blank ( 16 ) with at least one first opening ( 17 , 18 , and 19 ) in the first photoresist layer ( 10 ) forming a patterned photomask blank ( 23 ), wherein each first opening ( 17 , 18 , and 19 ) comprises a first diameter ( 20 , 21 , and 22 ); c. etching through the first openings ( 17 , 18 , and 19 ) into the first photoresist layer ( 10 ) forming at least one second opening ( 26 , 27 , and 28 ) in the metalized layer ( 14 ) forming an etched blank ( 34 ), wherein each second opening ( 26 , 27 , and 28 ) comprises a second diameter ( 30 , 31 , and 32 ); d. removing the first photoresist layer ( 10 ) from the etched blank ( 34 ) forming a patterned structure ( 36 ); e. applying a second photoresist layer ( 38 ) to the patterned structure ( 36 ) forming a mandrel ( 40 ); f. patterning the mandrel ( 40 ) forming at least one ring ( 42 , 43 , and 44 ) over each second opening ( 26 , 27 , and 28 ), wherein each ring ( 42 , 43 , and 44 ) comprises an outer diameter larger than the second diameter ( 30 , 31 , and 32 ) and an inner diameter smaller than the second diameter ( 30 , 31 , and 32 ) forming a patterned mandrel ( 46 ); g. plating the patterned mandrel ( 46 ) with a metal ( 47 ) forming an orifice plate on the patterned mandrel ( 46 ); and h. separating the orifice plate from the patterned mandrel ( 46 ), wherein the orifice plate comprises a high density array of nozzles.