Patent ID: 7252775

Claim:
A method of fabricaring inkjet nozzles on a substrate, each nozzle comprising a nozzle chamber and an actuator suspended in the nozzle chamber, each nozzle chamber comprising a roof having a nozzle aperture defined therein and sidewalls extending from the roof to the substrate, the method comprising the steps of: (a) depositing a layer of first sacrificial photoresist onto the substrate; (b) defining actuator scaffolds in the first sacrificial photoresist; (c) depositing actuator material onto the actuator scaffolds; (d) etching the actuator material to define actuators; (e) depositing a layer of second sacrificial photoresist to cover the actuators; (f) defining openings in the second sacrificial photoresist, the openings being complementary to chamber sidewalls; (g) depositing roof material onto the second sacrificial photoresist and into the openings, thereby forming the roof and sidewalls of each chamber; (h) etching nozzle apertures through each roof; and (i) removing the first and second sacrificial photoresist exposed through the nozzle apertures.