Method of forming an orifice array for a high density ink jet printhead

A method of forming an orifice m a cover plate for an ink jet printhead, said cover plate having a front surface and intersecured layer components comprising a removable backing, a front side layer formed from an ablatable material, and an intermediate layer formed from an adhesive material, comprising the steps of:

• forming an indentation in said cover plate extending through said removable backing and said intermediate layer and partially into said front side layer, said indentation exposing an interior surface of said front side layer;
• and
• forming an aperture in said indentation, said aperture having a smaller cross-sectional area than said indentation and extending from a portion of said exposed interior surface of said front side layer to said front surface of said cover plate,
• whereby said removable backing is removed and said intermediate layer is provided to adhere said front side layer to the ink jet printhead without said adhesive material clogging said aperture.

A method of forming an ink jet printhead, comprising the steps of:

• providing a main body portion having a front end and at least one ink-carrying channel axially extending through said main body portion and in communication with said front end;
• providing a cover plate having front and back surfaces;
• forming, in said cover plate, an ink-ejecting orifice corresponding to each of said at least one ink-carrying channel, said orifice comprising an indentation into said back surface, said indentation exposing an interior surface of said cover plate, and an aperture having a smaller cross-sectional area than said indentation, said aperture extending from a portion of said exposed interior surface to said front surface of said cover plate;
• and
• mounting said cover plate to said main body portion such that each of said at least one ink-carrying channel is in communication with said corresponding ink-ejecting orifice.