Patent ID: 8490282

Claim:
A method of manufacturing a catcher including a liquid drop contact surface upon which non-print liquid drops impinge, the liquid drop contact surface including pores through which liquid from the impinging non-print liquid drops is drawn, the catcher including fluid return channels through which the liquid flows after being drawn through the pores of the liquid drop contact surface, the method comprising: providing a catcher face material layer; providing a reinforcing structure material layer that is in mechanical contact with the catcher face material layer; forming the liquid drop contact surface by forming the pores in the catcher face material layer using a first etching process that is controlled by a first photolithographic mask; forming the fluid return channels by forming openings in the reinforcing structure material layer using a second etching process that is controlled by a second photolithographic mask; and fluidically connecting the openings in the reinforcing structure and the pores of the catcher face using a material removal process so that liquid drawn through the pores of the catcher face material layer flows through the openings of the reinforcing structure.