Patent ID: 7368044

Claim:
A process for forming a multilayer three-dimensional structure, comprising: (a) forming a first layer comprising at least one structural material and at least one sacrificial material on a substrate that may include one or more previously formed layers each formed from the at least one structural material and the at least one sacrificial material; and (b) repeating the forming of (a) one or more times to form at least one subsequent layer on and adhered to the first layer or on and adhered to a previously formed subsequent layer to build up a three-dimensional structure from a plurality of adhered layers; wherein the forming of at least one layer of the plurality of adhered layers, comprises: (1) supplying a mask that comprises at least one void and at least one surrounding protrusion of material; (2) bringing the at least one protrusion of the mask into proximity to or into contact with the substrate or a selected previously formed layer so as to form at least one electrochemical process pocket having a desired registration with respect to the substrate or the selected previously formed layer, and providing a desired electrolyte within the at least one electrochemical process pocket; and (3) applying a desired electrical activation between at least one electrode, that may be part of the mask or separate therefrom, and the substrate or the selected previously formed layer, such that a desired modification of the substrate or the selected previously formed layer occurs during the forming of the at least one layer, wherein the mask comprises at least two different materials where the material that is brought in proximity to or in contact with the substrate or the selected previously formed layer is less conformable than another material from which the mask is comprised.