Abstract:
A method for forming microscopic scale structures by selective etching of a doped substrate is disclosed. A substrate is prepared for etching by forming relatively deep doped substrate regions with substantially faster dissolution rates in selected etchants than the surrounding pure substrate. The doped regions are defined by depositing the dopants on the substrate using a lithographic process. Doped regions with high aspect ratios are produced by thermomigrating the deposited metal into the substrate. The substrate is then etched in an etchant that selectively removes the doped regions, while leaving the surrounding pure substrate essentially unetched. Thus, the doped region can be used to define a high aspect ratio feature, such as a microtubulc or micro-channel. Additionally, methods for forming more complex structures by depositing a variety of different dopants in a pattern on a substrate are disclosed. Combinations of the foregoing selective doping methods with a mask-and-etch process are further disclosed, useful for making structures such as a microscopic needle having a central microtubule for injecting fluids.