Patent ID: 7160429

Claim:
An electrochemical fabrication process for producing a three-dimensional structure, comprising a structural component and an enclosure, from a plurality of adhered layers, the process comprising: (A) depositing at least a portion of a first layer onto a substrate, wherein the substrate may comprise previously deposited material; and (B) forming a plurality of layers such that a second layer is formed on the first layer and such that each successive layer is formed adjacent to and adhered to a previously formed layer, and wherein the formation of at least some of the plurality of layers comprises an electrochemical deposition or electrochemical etching operation; wherein the plurality of layers comprise at least three different materials and wherein the layers contain patterns of the at least three different materials comprising: (1) a desired structural component that is to be protected and that is formed from at least one structural material; (2) a protective enclosure that is formed at least in part from a structural material, wherein at least one portion of the enclosure at least partially surrounds the desired structural component, and wherein the enclosure is limited by at least one opening therein; (3) a sealing material located near the at least one opening; and (4) a sacrificial material located at least partially between the desired structural component to be protected and the at least a portion of the enclosure; wherein after formation of the layers at least a portion of the sacrificial material located between the desired structural component and the at least a portion of the enclosure is removed; and wherein after the removal of the sacrificial material, the sealing material is made to temporarily flow and seal the at least one opening to block or significantly limit a passage of material from an outside of the enclosure to an inside of the enclosure via the at least one sealed opening.