Patent ID: 8043931

Claim:
A method for forming a multi-layer silicon structure, comprising: (a) forming a plurality of individual layers, wherein each of the plurality of individual layers comprises at least silicon wherein the at least silicon forms a pattern; wherein at least one of the plurality of individual layers comprises a plurality of discrete silicon features wherein the discrete silicon features are held together with at least one sacrificial material and wherein at least a portion of the discrete silicon features is exposed on at least one surface of the at least one layer; and wherein a thickness of at least one of the plurality of individual layers is greater than a predetermined value; (b) aligning the plurality of individual layers; (c) attaching at least the plurality of individual layers together, wherein at least a portion of the exposed portion of the discrete silicon features of the at least one layer comprising the discrete silicon features is attached to a receiver and wherein after the at least one layer that is thicker than the predetermined value is attached to a receiver, the thickness is reduced to the predetermined value; and (d) removing the at least one sacrificial material to release the discrete silicon features from the at least one sacrificial material after the step of (c).