Patent ID: 8268156

Claim:
A process for fabricating a multi-layer micro-electro-mechanical system, comprising: a) providing a primary metal structure supported by a substrate; b) depositing a first sacrificial secondary metal in a thin layer around the primary metal structure and over the entire surface of the substrate; c) depositing a second sacrificial secondary metal in a thick layer around first sacrificial secondary metal and over the entire surface of the substrate; d) machining the primary and first and second sacrificial secondary metals; e) repeating steps (a)-(d) above until a desired multi-layered structure is fabricated; and f) etching away the first and second sacrificial secondary metals from the machined primary metal structure to form a multi-layered micro-electro-mechanical system; wherein the deposited second sacrificial secondary metal is of a lower density than the first sacrificial secondary metal, such that the combination of these metals does not cause the substrate to warp.