A method of fabricating a high-aspect ratio micro-mechanical device or
system with dimensions that can vary from nanometers to millimeters is
disclosed. According to the method, a tool master with a high-aspect
ratio, submicron lateral resolution and vertical dimensions substantially
corresponding to the vertical dimensions of the device or system is
formed. The tool master and a substrate sized for the device or system
are heated to a temperature at which the substrate becomes compliant. The
heated tool master and substrate are then pressed together so as to
imprint the shape and form of the tool master into the substrate. The
temperature of the tool master and substrate are then lowered, whereupon
the tool master and substrate are separated and cooled to ambient
temperature. The tool master can have a plurality of duplications to form
a plurality of devices or systems. The substrate is composed of a
laminate comprised of a sacrificial layer and a structural layer. The
sacrificial layer can be removed to release the structural layer and
thereby form a movable device or system.