3D fabrication by stacking prepatterned, rigidly held membranes

Abstract

The authors describe an approach to fabricating high resolution, complex 3D structures based on the stacking of thin membranes that have been patterned in advance. The membranes are attached to a rigid frame by means of tethers that are strong enough to permit normal handling but can be cleaved after bonding. The tether shape was designed using finite-element analysis to enable clean cleavage at a specific location so that fragments are avoided that would interfere with the bonding of subsequent layers. The authors used 12 × 12 mm SiNx membranes, 350 nm thick, patterned with a square array of holes at 600 nm pitch and demonstrate the stacking of three layers.