Method of making a microfluid ejection head structure

1. A method of making a micro-fluid ejection head structure, the method comprising:

applying a removable mandrel material to a semiconductor substrate wafer containing fluid ejection actuators on a device surface thereof, wherein the mandrel material is shaped to provide fluid chamber and fluid channel locations on the semiconductor substrate wafer;

applying a micro machinable material to the shaped mandrel and the device surface of the substrate wafer to provide a nozzle plate and flow feature layer on the shaped mandrel and device surface, the nozzle plate and flow feature layer having a thickness ranging from about 10 to about 80 microns;

forming a plurality of nozzle holes in the nozzle plate and flow feature layer; and

removing the shaped mandrel material from the device surface of the substrate wafer to provide fluid chambers and fluid channels in the nozzle plate and flow feature layer.

2. The method of claim 1 , wherein the act of applying the micro machinable material comprises dry-spraying a photoresist material in a highly volatile carrier fluid onto the device surface of the shaped mandrel material and device surface whereby the carrier fluid substantially evaporates so that the photoresist material is applied to the shaped mandrel material and device surface in solid rather than liquid form.

3. The method of claim 2 , wherein the dry-spraying act comprises spray coating two or more spray-coated layers onto the shaped mandrel material and the device surface of the substrate wafer to provide the spray-coated layer.

4. The method of claim 1 , wherein the nozzle plate and flow feature layer comprises a negative photoresist material.

5. The method of claim 1 , wherein the mandrel material comprises a photoresist material and the mandrel material is shaped using a photo imaging and developing technique.

6. The method of claim 1 , wherein the mandrel material is applied to the semiconductor substrate wafer by spin coating the mandrel material onto the device surface of the substrate wafer.

7. The method of claim 1 , wherein the mandrel material is applied to the semiconductor substrate wafer using a dry film lamination technique.

8. The method of claim 1 , wherein the act of forming nozzle holes in the nozzle plate and flow feature layer comprises dry etching the nozzle plate and flow feature layer.

9. The method of claim 1 , wherein the act of forming nozzle holes in the nozzle plate and flow feature layer comprises a photo imaging and developing technique.

10. The method of claim 1 , wherein the nozzle plate and flow feature layer comprises a composition selected from the group consisting of epoxy, acrylate, polyimide, novolac, diazonaphthaquinone, cyclized rubber, chemically amplified resists, and the like.

11. The method of claim 1 , further comprising forming a plurality of fluid supply slots in the substrate wafer before applying the removable mandrel material to the wafer.

12. The method of claim 1 , further comprising forming a plurality of fluid supply slots in the substrate wafer after applying the removable mandrel material to the wafer.

13. The method of claim 1 , wherein the nozzle plate and flow feature layer is applied to the shaped mandrel and device surface of the substrate using a lamination technique.

14. The method of claim 1 , further comprising applying at least one of a passivation layer and a planarization layer to the device surface.

15. The method of claim 1 , further comprising modifying a surface of the micro machinable material by at least one of applying a chemical to the surface of the micro machinable material, applying a plasma to the surface of the micro machinable material, and grinding the surface of the micro machinable material using chemical mechanical polishing, wherein the modification can affect at least one of a planarization of the surface of the micro machinable material, a wetting characteristic of the surface of the micro machinable material, and an overall thickness of the micro machinable material.

16. A method of making a micro-fluid ejection head structure, the method comprising:

forming a plurality of fluid supply slots in a semiconductor substrate wafer having a device surface thereon;

applying a removable mandrel material to the device surface of the semiconductor substrate wafer, wherein the mandrel material is shaped to provide fluid chamber and fluid channel locations on the semiconductor substrate wafer;

dry-spraying the shaped mandrel material and the device surface of the substrate wafer with a micro machinable material in a carrier fluid to provide a spray-coated layer on the shaped mandrel and device surface of the substrate wafer, the spray-coated layer having a thickness ranging from about 10 to about 80 microns;

forming a plurality of nozzle holes in the spray-coated layer; and

removing the shaped mandrel material from the device surface of the substrate wafer to provide fluid chambers and fluid channels in the spray-coated layer.

17. The method of claim 16 wherein the dry-spraying act comprises spray coating a photoresist material in a highly volatile carrier fluid onto the device surface of the substrate whereby the carrier fluid substantially evaporates so that the photoresist material is applied to the shaped mandrel material and device surface in solid rather than liquid form.

18. The method of claim 16 , further comprising treating the device surface of the semiconductor substrate wafer before applying the mandrel material to increase adhesion between the mandrel material and the device surface.