Method for forming thermal-ink heater array using rectifying material

A fabrication method for a heater array in an ink jet printer, the method comprising the steps of:

• forming an insulating substrate;
• depositing a first material layer atop the insulating substrate;
• patterning the first material layer;
• depositing a first insulating layer atop the patterned first material layer;
• patterning a plurality of contact windows in the first insulating layer at desired heating locations;
• depositing a second material layer atop the patterned first insulating layer such that the first and second material layers are in physical contact with each other through the contact windows in the first insulating layer;
• forming contacts on the first material layer;
• and
• forming contacts on the second material layer,
• wherein each physical contact region between the first and second material layers forms a vertically extending resistive diode junction within the contact window at the desired heating locations, the resistive diode junction in a forward biased condition transferring conductive heat directly to ink in the ink jet print head while simultaneously limiting forward current in said resistive diode junction.