Mesoscale and microscale device fabrication methods using split structures and alignment elements

A method for forming at least a portion of a three-dimensional device having a desired configuration, comprising:

• a. forming at least first and second portions of a structure from a plurality of adhered layers of at least one structural material where the first portion has a first surface and the second portion has a second surface where the first and second surfaces are separated from one another during formation of the layers but which are to be located in contact or in proximity to one another in the desired configuration;
• and
• b. rotating at least one of the first and second portions relative to the other to bring the first and second surfaces into contact or into proximity,
• wherein the forming comprises depositing at least one material selectively onto a substrate or previously deposited material via one or more openings in a masking material that is adhered to the substrate or previously deposited material, and
• wherein the forming comprises forming one or more alignment structures which aid in locating the first and second surfaces in proximity or in contact and/or which aid in guiding the first and second surfaces in proximity or in contact.

A method for forming at least a portion of a three-dimensional device having a desired configuration, comprising:

• a. forming at least first, second, and third portions of a structure from a plurality of adhered layers of at least one structural material where the first portion has a first surface and the second portion has a second surface and the third portion has a third surface, where the first, second, surfaces are separated from one another during formation of the layers but which are to be located in contact or in proximity to one another in the desired configuration, and where the third surface is separated from the first and second portions during formation but is to be located in contact or in proximity to a surface of one of the first or second portions;
• and
• b. moving at least one of the first and second portions relative to the other to bring the first and second surfaces into contact or into proximity,
• c. moving at least one of the third or combined first and second portions relative to the other to bring the third and combined first and second portions into contact or into proximity, wherein at least one of the moving steps comprises rotating.