Lithographically defined and etched spring structures are produced
by various methods such that they avoid the formation of a plated metal wedge on
an underside of the spring structure after release. A post is utilized to offset
the spring from an underlying substrate by a distance greater than the thickness
of the plated metal. A trench is etched into the substrate below the spring to
provide clearance during deflection of the spring. Another spring includes a knee
(bend) that provides the necessary clearance during deflection. A plating process
is limited to the upper side of another spring. A released spring is used as a
shadow mask for patterning resist that prevents wedge formation during plating.
Various tip arrangements are disclosed that can be utilized with each spring structure