Disc drive slider with bar reducing load/unload damage

On a slider substrate, a process for providing a dull end on a bar that has a bar edge surrounding a bar centerline, the process comprising:

• adhering a resist layer over the slider substrate;
• providing a radiation source capable of altering the resist layer during an exposure time;
• providing a mask between the radiation source and the resist layer, the mask having an opacity pattern that gradually varies from a higher opacity level to a lower opacity level between the bar centerline and the bar edge;
• selecting the exposure time to cure the resist layer, the curing varying gradually from a more complete alteration to a less complete alteration of the resist layer between the bar centerline and the bar edge;
• rinsing away a first portion of the resist layer, leaving a second developed portion of the resist layer that is adhered to the slider substrate over the bar;
• etching the slider substrate, the etching undercutting the second developed portion of the resist layer to form the dull end;
• and
• removing the second developed portion of the resist layer.

A slider rotatably attachable to a suspension for flying over an air bearing layer, the slider being subject to misalignment with a disc surface in a disc drive, the slider comprising:

• a slider substrate having sidewall surfaces that include side edge surfaces and a trailing edge surface and having an air bearing surface that includes a peripheral edge;
• a read/write head deposited on the trailing edge surface;
• a bar disposed between a sidewall surface and the peripheral edge;
• a bar having a dull end that contacts the disc surface when the slider is misaligned with the disc surface.