A single, controlled etch step can be used to form a sharp tip feature
along a sidewall of an etch feature. An etch process is used that is
selective to a layer of tip material relative to the substrate upon which
the layer is deposited. A lag can be created in the etch, such that the
etch rate is slower near the sidewall. The sharp tip feature is formed
from the same layer of material used to create the etch feature. The
sharp tip feature can be used to decrease the minimum critical dimension
of an etch process, such as may be due to the minimum resolution of a
photolithographic process. The novel tip feature also can be used for
other applications, such as to create a microaperture for a
photosensitive device, or to create a micromold that can be used to form
objects such as microlenses.