A novel method of forming a released metal spring structure is described.
In the method, a release layer including a blowing agent is deposited,
usually printed, over portions of a substrate. A metal film is deposited
over both the release layer and the substrate. The release layer is then
heated such that the blowing agent decomposes releasing a portion of the
metal film. The metal film curls out of the plane of the substrate to
form a spring structure.