Single-mask processing of micromechanical piercing structures using ion milling (biomedical tissue fasteners)

A useful method for transferring mask patterns over large distances using ion milling is described. This technique exploits the anisotropy of a collimated ion beam to etch the projection of a stencil mask pattern into a thin film. This method avoids the difficulties associated with photoresist processing on highly nonplanar substrates, and thus provides an alternative process avenue for the development of three-dimensional microstructures. The technique is demonstrated by fabricating arrays of high aspect ratio barbs, which are intended for use in tissue fasteners in biomedical applications.<<ETX>>