High-precision printed structures
An example of a printed structure comprises a target substrate and a structure protruding from a surface of the target substrate. A component comprising a component substrate separate and independent from the target substrate is disposed in alignment with the structure on the surface of the target substrate within 1 micron of the structure. An example method of making a printed structure comprises providing the target substrate with the structure protruding from the target substrate, a transfer element, and a component adhered to the transfer element. The component comprises a component substrate separate and independent from the target substrate. The transfer element and adhered component move vertically toward the surface of the target substrate and horizontally towards the structure until the component physically contacts the structure or is adhered to the surface of the target substrate. The transfer element is separated from the component.
1. A printed structure, comprising:
a target substrate and a structure protruding from a surface of the target substrate; and
a component in alignment with the structure, the component comprising a component substrate separate and independent from the target substrate,
wherein the component is disposed on the surface of the target substrate laterally adjacent to and within one micron of a top of the structure, and
wherein the component comprises a broken or separated tether.
2. The printed structure of claim 1 , wherein the component is in contact with the structure.
3. The printed structure of claim 1 , wherein the structure comprises a broken or separated tether.
4. The printed structure of claim 1 , wherein the component and the structure are aligned optical elements on the surface of the target substrate.
5. The printed structure of claim 1 , wherein either or both of the component and the structure comprise one or more of a laser, a light-emitting diode, a light sensor, and an optical fiber.
6. The printed structure of claim 1 , wherein the component has a length or a width or a length and a width less than or equal to 200 microns.
7. The printed structure of claim 1 , wherein (i) the structure has a flat face adjacent to the component, (ii) the component has a substantially flat face adjacent to the structure, or (iii) both (i) and (ii).
8. The printed structure of claim 7 , wherein the structure has a flat face substantially orthogonal to the surface of the target substrate.
9. The printed structure of claim 1 , wherein the structure, the component, or both the structure and the component are operable to receive or emit light.
10. The printed structure of claim 9 , wherein the component is disposed and operable to emit light to or receive light from the substrate, wherein the structure is disposed and operable to emit light to or receive light from the substrate, or wherein the component is disposed and operable to emit light to or receive light from the structure.
11. The printed structure of claim 9 , comprising a controller disposed on the surface of the substrate and wherein (i) the controller is electrically connected to the component and operable to control operation of the component, (ii) the controller is electrically connected to the structure and operable to control operation of the structure, or (iii) both (i) and (ii).
12. The printed structure of claim 1 , comprising an encapsulation layer disposed at least partly over the component, the structure, and any gap between the component and the structure.
13. The printed structure of claim 12 , wherein the encapsulation layer comprises or is coated with a light-reflective layer.
14. The printed structure of claim 1 , wherein the component has a thickness equal to or greater than a thickness of the structure.
15. The printed structure of claim 1 , wherein the component comprises a component material, the target substrate comprises a substrate material, and the component material is substantially different from the substrate material.
16. The printed structure of claim 1 , comprising a reflective material disposed (i) between the component and the target substrate, (ii) between the structure and the target substrate, or (iii) both (i) and (ii).
17. The printed structure of claim 1 , wherein the component is a first component and the printed structure comprises a second component disposed on the surface of the target substrate within one micron of the first component and the second component comprises a broken or separated tether.
18. The printed structure of claim 1 , wherein the component comprises connection posts.
19. The printed structure of claim 1 , wherein a height of the structure over the target substrate is less than or equal to a height of the component over the target substrate.
20. The printed structure of claim 1 , wherein the structure has a side adjacent to the component that is substantially at 90 degrees or more to the surface of the target substrate.
21. The printed structure of claim 1 , wherein the component is disposed on the surface of the target substrate within 0.75 microns of the structure.
22. A printed structure, comprising:
a substrate and a structure protruding from a surface of the substrate; and
a component in alignment with the structure, the component comprising a component substrate separate and independent from the substrate,
wherein the component is disposed on the surface of the substrate within one micron of a top of the structure and not on the structure, and
wherein the component comprises a broken or separated tether.
23. A printed structure, comprising:
a substrate and a structure protruding from a surface of the substrate; and
a component in alignment with the structure, the component comprising a component substrate separate and independent from the substrate,
wherein the component is disposed on the surface of the substrate laterally adjacent to and within one micron of a top of the structure, and
wherein the component is non-native to the substrate.
24. The printed structure of claim 23 , wherein the structure is non-native to the substrate.