Thick film MEMS process using reverse lift-off

The lift-off process is a microfabrication technique that has the capability of forming thin film structures. However, several issues, such as structural shape and burr formation, arise when applying this method to the formation of thick film structures. Thick film structures formed through the lift-off process exhibit a mountainous cross-sectional shape and non-uniform film thickness due to variations in the width of the structure. These challenges make it difficult to apply the method to MEMS. While the reverse lift-off process addresses some of the structural shape problems, its initial development using metal molds makes it challenging to directly apply to MEMS without modification. Therefore, this paper proposes an adaptation to the Si process and presents a method to reduce burrs. The microfabrication characteristics are evaluated by comparing the cross-sectional shapes of thick metallic glass structures formed through both the lift-off and reverse lift-off processes. The structures formed through the reverse lift-off process exhibit a rectangular cross-sectional shape, and the film thickness remains consistent regardless of the structure's width. However, burrs persist on the backside edge of the structure, which hinders its application to MEMS. This paper confirms that pre-etching the underlying Si substrate into an inverse tapered shape effectively reduces burrs. As an illustration of the improved reverse lift-off process applied to MEMS, MEMS mirror structures are fabricated, and their resonance frequency closely aligns with the design value.