Patent ID: 7459400

Claim:
A method for fabricating a patterned layer structure on a substrate such that the patterned layer structure includes first and second layer portions separated by a void, the method comprising: forming a lift-off pattern over the substrate by depositing a printing fluid onto a base layer such that the printing fluid attaches itself to the base layer through a wetting action, whereby the printing fluid solidifies to form said lift-off pattern such that the lift-off pattern has a rounded cross-sectional profile; forming a blanket layer over the substrate such that first and second portions of the blanket layer are located on opposite sides of the lift-off pattern, a third portion located over the liftoff pattern, and attack point portions respectively extending between the third portion and the first and second portions, wherein the blanket layer is formed such that the attack point portions are thinner than the first, second and third portions; depositing a source/drain metal layer over the liftoff pattern such that the source/drain metal layer includes first and second portions respectively located on opposing sides of the liftoff pattern; patterning a mask over the first and second portions of the blanket layer such that the patterned mask extends over the lift-off pattern; removing portions of the blanket layer exposed around the patterned mask, and the patterned mask and the lift-off pattern.