The current invention provides for encapsulated release structures, intermediates
thereof and methods for their fabrication. The multi-layer structure has a capping
layer, that preferably comprises silicon oxide and/or silicon nitride, and which
is formed over an etch resistant substrate. A patterned device layer, preferably
comprising silicon nitride, is embedded in a sacrificial material, preferably comprising
polysilicon, and is disposed between the etch resistant substrate and the capping
layer. Access trenches or holes are formed in to capping layer and the sacrificial
material are selectively etched through the access trenches, such that portions
of the device layer are release from sacrificial material. The etchant preferably
comprises a noble gas fluoride NGF2x (wherein Ng=Xe, Kr or Ar: and where
x=1, 2 or 3). After etching that sacrificial material, the access trenches are
sealed to encapsulate released portions the device layer between the etch resistant
substrate and the capping layer. The current invention is particularly useful for
fabricating MEMS devices, multiple cavity devices and devices with multiple release features.