Methods of making MEMS devices including interferometric modulators
involve depositing various layers, including stationary layers, movable
layers and sacrificial layers, on a substrate. Voids are formed in one or
more of the various layers so as to form a non-planar surface on the
movable and/or the stationary layers. The voids are formed to extend
through less than the entire thickness of the layer where they are being
formed. Other layers may be formed over the formed voids. Removal of the
sacrificial layer from between the resulting non-planar movable and/or
stationary layers results in a released MEMS device having reduced
contact area between the movable and stationary layers when the MEMS
device is actuated. The reduced contact area results in lower adhesion
forces and reduced stiction during actuation of the MEMS device. These
methods may be used to manufacture released and unreleased
interferometric modulators.