A method and apparatus for fabricating a MEMS apparatus having a device
layer with an optical surface that is supported by a pedestal on a planar
support layer that is suspended for movement with respect to a base
support by hinge elements disposed in a different plane from the planar
support layer. The surface area of the optical surface is maximized with
respect to the base support to optimized the fill factor of the optical
surface and afford a high passband. The height of the pedestal is
selected to position the device layer sufficiently above the base support
to afford an unobstructed predetermined angular rotation about each axis.
The hinges may be made of thin-film material, fabricated by way of
surface micromachining techniques. The hinges are disposed underneath the
device layer enabling the optical surface to be maximized so that the
entire surface becomes usable (e.g., for optical beam manipulation). MEMS
devices afford an array of MEMS mirrors with a high optical fill factor
and high passband. Further, use of both bulk and surface micromachining
techniques gives a MEMS device with a large and flat mirror and flexible
hinges capable of a substantial rotational range at modest electrostatic
drive voltages.