This paper reports on a study of a methodology for fabrication of arbi
trarily shaped silicon structures using standard IC manufacturing proc
esses. Particular emphasis is put on the design of halftone transmissi
on masks for the lighography step required in the fabrication process
of mechanical, optical or electronics components. The design and exper
imental investigation of gray-tone masks was supported by lithography
simulation. Results are presented for simulated gray-tone patterns as
well as experimental trials.