CLAIMS What is claimed is:
1. A cutting tool, comprising: a blade comprising first cutting edge surface, a second cutting edge surface, a cutting edge defined by an intersection of said first and second cutting edge surfaces, and a first registration surface spaced from said cutting edge and parallel with said first cutting edge surface; and a blade handle interconnected with said blade and comprising a first registrant that interfaces with at least part of said first registiation surface. 2. A cutting tool, as claimed in Claim 1, wherein: said blade further comprises top and bottom surfaces that are planar and disposed in parallel relation, wherein said first cutting edge surface is disposed at an angle relative to and intersects with said top surface, and wherein said bottom surface comprises said second cutting edge surface. 3. A cutting tool, as claimed in Claim 1, wherein: said blade further comprises top and bottom surfaces that are planar and disposed in parallel relation, wherein both said first cutting edge surface and said first registration surface are disposed at an angle relative to and intersect with said top surface, wherein said bottom surface comprises said second cutting edge surface, and wherein said first registration surface is disposed at an angle relative to and intersects with said bottom surface.
4. A cutting tool, as claimed in Claim 1, wherein: said first cutting edge surface extends from a first edge to said cutting edge, wherein said first registration surface extends from a second edge to a third edge, wherein said first and second edges are disposed within a first reference plane, wherein said cutting edge and said third edge are disposed within a second reference plane, and wherein said first and second reference planes are parallel.
5. A cutting tool, as claimed in Claim 1, wherein: said blade comprises a second registiation surface spaced from said cutting edge and parallel with said first cutting edge surface; and wherein said blade handle comprises a second registrant that interfaces with at least part of said second registiation surface.
6. A cutting tool, as claimed in Claim 5, wherein: said first and second registration surfaces are coplanar.
7. A cutting tool, as claimed in Claim 1, wherein: said blade comprises a concave first registration cavity spaced from said cutting edge and comprising first and second ends with said first end being disposed between said cutting edge and said • second end, wherein said second end comprises said first registration surface.
8. A cutting tool, as claimed in Claim 7, wherein: said first registiation cavity extends entirely through said blade.
9. A cutting tool, as claimed in Claim 7, wherein: said blade comprises a planar top surface, wherein said first end of said first registration cavity is peφendicular to said planar top surface, and wherein said first registration surface is disposed at an angle other than peφendicular relative to said planar top surface.
10. A cutting tool, as claimed in Claim 7, wherein: said first registiant is separated from said first end by a space. 11. A cutting tool, as claimed in Claim 7, wherein: said blade further comprises a concave second registration cavity spaced from said cutting edge and comprising third and fourth ends with said third end being disposed between said cutting edge and said fourth end, wherein said fourth end comprises a second registration surface that is parallel with said first cutting edge surface and coplanar with said first registration surface; and wherein said blade handle comprises a second registiant that interfaces with at least part of said second registration surface.
12. A cutting tool, as claimed in Claim 1, wherein: an interface between said first registrant and said first registration surface is limited to being at least substantially along a line.
13. A cutting tool, as claimed in Claim 1, wherein: said blade further comprises top and bottom surfaces, wherein an intersection between said first registration surface and said top surface defines a first edge, and wherein an intersection between said first registration surface and said bottom surface defines a second edge.
14. A cutting tool, as claimed in Claim 13, wherein: said first registrant interfaces with said first registration surface closer to said second edge than said first edge.
15. A cutting tool, as claimed in Claim 13, wherein: said first registrant interfaces with said first registration surface along said second edge.
16. A cutting tool, as claimed in Claim 13, wherein: said first registrant extends below said second edge.
17. A cutting tool, as claimed in Claim 1, wherein: said blade handle comprises a second registiant, wherein said second registrant disposes said blade handle in a predetermined position relative to a microkeratome when said cutting tool is installed on the microkeratome. 18. A cutting tool, comprising: a blade comprising a first cutting edge surface, a second cutting edge surface, a cutting edge defined by an intersection of said first and second cutting edge surfaces, a concave first registration cavity spaced from said cutting edge and comprising first and second ends with said first end being disposed between said first cutting edge and said second end; and a blade handle interconnected with said blade and comprising a first registrant that extends within said first registration cavity, wherein said first registrant interfaces with at least part of said second end of said first registration cavity and is spaced from said first end of said first registration cavity. 19. A cutting tool, as claimed in Claim 18, wherein: said first registration cavity extends entirely through said blade.
20. A cutting tool, as claimed in Claim 18, wherein: said blade comprises a planar top surface, wherein said first end of said first registration cavity is peφendicular to said planar top surface, and wherein said second end of said first registiation cavity is disposed at an angle other than peφendicular relative to said planar top surface.
21. A cutting tool, as claimed in Claim 18, wherein: said first registiant is separated from said first end of said first registiation cavity by a distance of at least about 1 millimeter. 22. A cutting tool, as claimed in Claim 18, wherein: said blade further comprises a concave second registration cavity spaced from said cutting edge and comprising third and fourth ends with said third end being disposed between said cutting edge and said fourth end; and
wherein said blade handle comprises a second registiant that interfaces with at least part of said fourth end and is spaced from said third end.
23. A cutting tool, as claimed in Claim 22, wherein: said first and second registrants are positioned along a reference axis that is parallel with said cutting edge.
24. A cutting tool, as claimed in Claim 22, wherein: said first and second registrants are equidistant from said cutting edge.
25. A cutting tool, as claimed in Claim 22, wherein: said second end of said first registiation cavity comprises a first registration surface that is spaced from said first cutting edge and parallel with said first cutting edge surface; wherein said fourth end of said second registration cavity comprises a second registiation surface that is spaced from said cutting edge and parallel with said first cutting edge surface; and wherein said second registiant interfaces with at least part of said second registiation surface.
26. A cutting tool, as claimed in Claim 25, wherein: said first and second registration surfaces are coplanar.
27. A cutting, tool, as claimed in Claim 18, wherein: said second end of said first registration cavity comprises a first registration surface that is spaced from said cutting edge and parallel with said first cutting edge surface, wherein said first registrant interfaces with at least part of said first registiation surface.
28. A cutting tool, as claimed in Claim 27, wherein: said blade further comprises top and bottom surfaces that are planar and disposed in parallel relation, wherein said first cutting edge surface is disposed at an angle relative to and intersects said top surface, and wherein said bottom surface comprises said second cutting edge surface.
29. A cutting tool, as claimed in Claim 27, wherein: said blade further comprises top and bottom surfaces that are planar and disposed in parallel relation, wherein both said first cutting edge surface and said first registration surface are disposed at an angle relative to and intersects with said top surface, wherein said bottom surface comprises said second cutting edge surface, and wherein said first
registration surface is disposed at an angle relative to and intersects with said bottom surface.
30. A cutting tool, as claimed in Claim 27, wherein: said first cutting edge surface extends from a first edge to said cutting edge, wherein said first registiation surface extends from a second edge to a third edge, wherein said first and second edges are disposed within a first reference plane, wherein said cutting edge and said third edge are disposed within a second reference plane, and wherein said first and second reference planes are parallel.
31. A cutting tool, as claimed in Claim 27, wherein: an interface between said first registrant and said first registration surface is limited to being at least substantially along a line.
32. A cutting tool, as claimed in Claim 27, wherein: said blade further comprises top and bottom surfaces, wherein an intersection between said first registration surface and said top surface defines a first edge, and wherein an intersection between said first registration surface and said bottom surface defines a second edge.
33. A cutting tool, as claimed in Claim 32, wherein: said first registrant interfaces with said first registiation surface closer to said second edge than said first edge. 34. A cutting tool, as claimed in Claim 32, wherein: said first registrant interfaces with said first registiation surface along said second edge.
35. A cutting tool, as claimed in Claim 32, wherein: said first registrant extends below said second edge. 36. A cutting tool, as claimed in Claim 18, wherein: said blade handle comprises a second registiant, wherein said second registrant disposes said blade handle in a predetermined position relative to a microkeratome when said cutting tool is installed on the microkeratome. 37. A cutting tool, comprising: a blade comprising first cutting edge surface, a second cutting edge surface, a cutting edge defined by an intersection of said first and second cutting edge surfaces, and a first registration surface spaced from said cutting edge and parallel with said first cutting edge surface.
38. A cutting tool, as claimed in Claim 37, wherein: said blade further comprises top and bottom surfaces that are planar and disposed in parallel relation, wherein said first cutting edge surface is disposed at an angle relative to and intersects with said top surface, and wherein said bottom surface comprises said second cutting edge surface.
39. A cutting tool, as claimed in Claim 37, wherein: said blade further comprises top and bottom surfaces that are planar and disposed in parallel relation, wherein both said first cutting edge surface and said first registration surface are disposed at an angle relative to and intersect with said top surface, wherein said bottom surface comprises said second cutting edge surface, and wherein said first registration surface is disposed at an angle relative to and intersects with said bottom surface.
40. A cutting tool, as claimed in Claim 37, wherein: said first cutting edge surface extends from a first edge to said cutting edge, wherein said first registration surface extends from a second edge to a third edge, wherein said first and second edges are disposed within a first reference plane, wherein said cutting edge and said third edge are disposed within a second reference plane, and wherein said first and second reference planes are parallel. 1. A cutting tool, as claimed in Claim 37, wherein: said blade comprises a second registration surface spaced from said cutting edge and parallel with said first cutting edge surface.
42. A cutting tool, as claimed in Claim 41, wherein: said first and second registration surfaces are coplanar.
43. A cutting tool, as claimed in Claim 37, wherein: said blade comprises a concave first registiation cavity spaced from said cutting edge and comprising first and second ends with said first end being disposed between said cutting edge and said second end, wherein said second end comprises said first registiation surface.
44. A cutting tool, as claimed in Claim 43, wherein: said first registration cavity extends entirely through said blade.
45. A cutting tool, as claimed in Claim 43, wherein: said blade comprises a planar top surface, wherein said first end of said first registration cavity is peφendicular to said planar top surface, and wherein said first
registration surface is disposed at an angle other than peφendicular relative to said planar top surface.
46. A cutting tool, as claimed in Claim 43, wherein: said blade further comprises a concave second registration cavity spaced from said cutting edge and comprising third and fourth ends with said third end being disposed between said cutting edge and said fourth end, wherein said fourth end comprises a second registration surface that is parallel with said first cutting edge surface and coplanar with said first registration surface.
47. A method for fabricating a blade from a substrate comprising a first surface, said method comprising the steps of: forming a masking layer on said first surface of said substrate; transferring a blade mask onto said masking layer; and etching said substrate through first and second openings in said blade mask that each expose a predetermined portion of said first surface of said substrate and that defines a first cutting edge surface and a first registration feature, respectively, for a first blade.
48. A method, as claimed in Claim 47, further comprising the step of: aligning said blade mask to a first crystallographic plane associated with said substrate before said transferring step.
49. A method, as claimed in Claim 47, wherein: said transferring step comprises using a technique selected from the group consisting of photomasking, masking, photolithography, and microlithography.
50. A method, as claimed in Claim 47, wherein: said etching step comprises an anisotropic etch of said substrate.
51. A method, as claimed in Claim 47, wherein: said etching step is a chemical etch.
52. A method, as claimed in Claim 47, wherein: said etching step comprises etching said substrate to the same crystallographic plane at each of first and second spaced locations to define said first cutting edge surface and said first registiation feature, respectively. 53. A method, as claimed in Claim 47, wherein: said etching step comprises simultaneously forming said first cutting edge surface and said first registiation feature.
54. A method, as claimed in Claim 47, wherein, said etching step comprises defining first and second planar and parallel surfaces at first and second locations, respectively, wherein said first cutting edge surface comprises said first planar surface, and wherein said first registiation feature comprises said second planar surface.
55. A method, as claimed in Claim 47, wherein: an intersection between said first cutting edge surface and a second surface of said substiate defines a first cutting edge, wherein said first and second surfaces of said substiate are oppositely disposed, and wherein said etching step comprises etching entirely through said substiate from only a first side of said substrate to define said first cutting edge.
56. A method, as claimed in Claim 55, wherein: said etching step comprises etching entirely through said substrate from only said first side of said substtate to define said first registration feature. 57. A method, as claimed in Claim 47, wherein: said etching step comprises etching entirely through said substiate from only one side of said substiate to define said first registration feature.
58. A method, as claimed in Claim 47, wherein: said etching step comprises etching said substiate to define a first registiation cavity, wherein said first registration cavity is defined in part by a first registiation surface, wherein said first registration surface comprises said first registiation feature, and wherein said first cutting edge surface and said first registiation surface are disposed in parallel relation.
59. A method, as claimed in Claim 58, wherein: said etching step comprises defining at least a portion of a perimeter of said first blade, wherein an entirety of said first registration cavity is disposed inwardly of said perimeter.
60. A method, as claimed in Claim 58, wherein: said etching step comprises etching entirely through said substiate to define said first registiation cavity.
61. A method, as claimed in Claim 58, wherein: said first cutting edge surface extends between a first edge and a first cutting edge, wherein said first edge is defined by an intersection of said first cutting edge surface and said first surface of said substrate; and
said first registration surface extends between second and third edges, wherein said second edge is defined by an intersection between said first registration surface and said first surface of said substrate, and wherein said third edge and said first cutting edge are disposed within a common reference plane that is parallel with said first surface. 62. A method, as claimed in Claim 61, wherein: said substtate comprises a second surface that is disposed opposite of said first surface, wherein said third edge is defined by an intersection between said first registration surface and said second surface of said substiate.
63. A method, as claimed in Claim 47, further comprising the steps of: etching said substrate through a third opening in said blade mask that exposes a predetermined portion of said first surface of said substrate and that defines a second registration feature for said first blade.
64. A method, as claimed in Claim 63, wherein: said etching step comprises etching said substrate to the same crystallographic plane at each of first, second, and third spaced locations to define said first cutting edge surface, said first registration feature, and said second registration feature, respectively.
65. A method, as claimed in Claim 63, wherein: said etching step comprises simultaneously forming said first cutting edge surface, said first registration feature, and said second registration feature. 66. A method, as claimed in Claim 63, wherein, said etching step comprises defining first, second, and third planar surfaces at first, second, and third locations, respectively, wherein said first cutting edge surface comprises said first planar surface, wherein said first registiation feature comprises said second planar surface, wherein said second registration feature comprises said third planar surface, and wherein said first planar surface is parallel with each of said second and third planar surfaces.
67. A method, as claimed in Claim 66, wherein: said second and third planar surfaces are disposed within a common reference plane. 68. A method, as claimed in Claim 63, wherein: said etching step comprises etching said substiate to define first and second registration cavities, wherein said first and second registiation cavities are defined in part by first and second registiation surfaces, respectively, wherein said first and second registration surfaces comprise said first and second registration features, respectively,
wherein said first cutting edge surface is disposed in parallel relation with each of said first and second registration surfaces, and wherein said first and second registration surfaces are disposed in spaced relation.
69. A method, as claimed in Claim 68, wherein: said etching step comprises defining a perimeter of said first blade, wherein an entirety of each of said first and second registration cavities is disposed inwardly of said perimeter.
70. A method, as claimed in Claim 68, wherein: said first and second registiation surfaces are disposed within a common reference plane.
71. A method for fabricating a blade from a substtate, said method comprising the steps of: executing a first etching step comprising etching said substtate at a first location to define a first cutting edge surface of a first blade; and executing a second etching step comprising etching said substtate at a second location to define a first registration cavity of said first blade, wherein said first location is spaced from said second location.
72. A method, as claimed in Claim 71, wherein: said first and second etching steps are executed concurrently using the same etchant.
73. A method, as claimed in Claim 72, wherein: said etchant is an anisotropic etchant.
74. A method, as claimed in Claim 71, wherein: said first etching step terminates upon reaching a first plane, wherein said second etching step terminates upon reaching a second plane, and wherein said first and second planes are parallel.
75. A method, as claimed in Claim 74, wherein: said first and second planes each correspond with a common crystallographic plane. 76. A method, as claimed in Claim 71, wherein: said second etching step comprises defining a first registration surface that is parallel with said first cutting edge surface.
77. A method, as claimed in Claim 71, wherein: said second etching step comprises etching entirely through said substtate.
78. A method, as claimed in Claim 71, wherein: said first cutting edge surface extends between a first edge and a first cutting edge, wherein said first edge is defined by an intersection of said first cutting edge surface and a first surface of said substiate; and said second etching step comprises defining a first registtation surface that extends between second and third edges, wherein said second edge is defined by an intersection between said first registtation surface and said first surface of said substiate, and wherein said third edge and said first cutting edge are disposed within a common reference plane that is parallel with said first surface. 79. A method, as claimed in Claim 78, wherein: said substiate comprises a second surface disposed opposite of said first surface, wherein said third edge is defined by an intersection between said first registiation surface and said second surface of said substiate.
80. A method, as claimed in Claim 71, further comprising the step of: executing a third etching step comprising etching said substiate to define at least a portion of a perimeter of said first blade, wherein an entirety of said first registiation cavity is disposed inwardly of said perimeter.
81. A method, as claimed in Claim 71, further comprising the steps of: executing a third etching step comprising etching said substiate at a third location to define a second registiation cavity of said first blade, wherein said third location is spaced from each of said first and second locations.
82. A method, as claimed in Claim 81, wherein: said first, second, and third etching steps are executed concurrently using the same etchant. 83. A method, as claimed in Claim 81, wherein: said first, second, and third etching steps comprise etching said substrate to the same crystallographic plane at each of said first, second, and third spaced locations to define said first cutting edge surface, said first registiation cavity, and said second registtation cavity, respectively. 84. A method, as claimed in Claim 81, wherein: said first, second, and third etching steps comprise simultaneously forming said first cutting edge surface, said first registtation cavity, and said second registration cavity, respectively.
85. A method, as claimed in Claim 81, wherein, said first, second, and third etching steps comprise defining first, second, and third planar surfaces, respectively, wherein said first cutting edge surface comprises said first planar surface, wherein part of said first registtation cavity is defined by said second planar surface, wherein part of said second registration cavity is defined by said third planar surface, and wherein said first planar surface is parallel with each of said second and third planar surfaces.
86. A method, as claimed in Claim 85, wherein: said second and third planar surfaces are disposed within a common reference plane.
87. A method, as claimed in Claim 81, further comprising the step of: executing a fourth etching step comprising etching said substrate to define at least a portion of a perimeter of said first blade, wherein an entirety of each of said first and second registtation cavities is disposed inwardly of said perimeter. 88. A method, as claimed in Claim 71, further comprising the steps of: forming a masking layer on a first surface of said substrate; transferring a blade mask onto said masking layer; and etching said substiate through first and second openings in said blade mask that each expose a predetermined portion of said first surface of said substrate and that defines said first cutting edge surface and said first registtation cavity, respectively.
89. A method, as claimed in Claim 88, further comprising the step of: aligning said blade mask to at least one crystallographic plane associated with said substrate before said transferring step.
90. A method, as claimed in Claim 88, wherein: said transferring step comprises using a technique selected from the group consisting of photomasking, masking, photolithography, and microlithography.
91. A method for fabricating a blade from a substrate, comprising the steps of: creating at least one opening that extends completely through said substrate, wherein said creating step comprises defining at least a portion of a perimeter of a first blade; and defining a first registiation feature from said substiate that is associated with said first blade, wherein said defining a first registration feature step is executed during said creating step.
92. A method for fabricating a blade from a substiate, comprising the steps of: creating at least one opening that extends completely through said substiate, wherein said creating step comprises defining at least a portion of a perimeter of a first blade; and defining a first registration feature from said substrate that is associated with said first blade, wherein said defining a first registtation feature step comprises using a same technique as said creating step.
93. A method for mounting a blade handle on a blade, comprising the steps of: positioning a wafer on a first fixture, wherein said wafer comprises a first blade; maintaining a first cutting edge of said first blade in spaced relation to said first fixture; and mounting a first blade handle on said first blade while on said first fixture. 94. A method, as claimed in Claim 93, wherein: said positioning step comprises positioning said wafer in a recess formed on an upper surface of said first fixture.
95. A method, as claimed in Claim 94, wherein: a perimeter of said recess at least substantially approximates a perimeter of said wafer.
96. A method, as claimed in Claim 93, wherein: said wafer comprises a first score associated with said first blade, wherein said positioning step comprises supporting said wafer with said first fixture directly under said first score, wherein said first blade may be separated from said wafer utilizing said first score.
97. A method, as claimed in Claim 96, further comprising the step of: aligning said first score with a predetermined crystal plane of said wafer.
98. A method, as claimed in Claim 93, wherein: said wafer comprises a first score associated with said first blade, wherein said positioning step comprises supporting said wafer such that said mounting step does not result in any net moment about said first score, wherein said first blade may be separated from said wafer utilizing said first score.
99. A method, as claimed in Claim 93, wherein: said wafer comprises a first cantilever, wherein said first blade is disposed on an end of said first cantilever, wherein said positioning step comprises supporting said first cantilever with said first fixture. 100. A method, as claimed in Claim 99, wherein: said positioning step comprises inhibiting any deflection of said first cantilever during said mounting step.
101. A method, as claimed in Claim 93, further comprising the step of: biasing said wafer toward said first fixture. 102. A method, as claimed in Claim 101, wherein: said biasing step comprises using a vacuum.
103. A method, as claimed in Claim 93, further comprising the step of: retaining said wafer on said first fixture using a vacuum.
104. A method, as claimed in Claim 93, wherein: said maintaining step comprises disposing said first cutting edge of said first blade above a first cutting edge cavity formed on an upper surface of said first fixture.
105. A method, as claimed in Claim 93, wherein: said mounting step comprises maintaining said first blade handle in spaced relation with an entirety of said first fixture. 106. A method, as claimed in Claim 93, wherein: said mounting step comprises applying an adhesive to at least one of said first blade handle and said first blade.
107. A method, as claimed in Claim 106, wherein: said adhesive is light curable, wherein said method further comprises disposing said first blade handle in a predetermined position relative to said first blade after said applying step, and thereafter exposing at least a portion of said adhesive to light to fix said first blade handle to said first blade.
108. A method, as claimed in Claim 93, wherein: said mounting step comprises disposing a first registrant extending from a lower surface of said first blade handle into a first registration cavity accessible through an upper surface of said first blade.
109. A method, as claimed in Claim 108, wherein: said disposing step of said mounting step comprises maintaining said first registrant in spaced relation with said first fixture.
110. A method, as claimed in Claim 109, wherein: said maintaining step of said disposing step comprises aligning said first registrant of said first blade handle with a first registrant cavity formed on an upper surface of said first fixture. 111. A method, as claimed in Claim 93, wherein: said mounting step comprises disposing first and second registrants extending from a lower surface of said first blade handle into first and second registration cavities accessible through an upper surface of said first blade.
112. A method, as claimed in Claim 111, wherein: said disposing step comprises supporting said first blade with said first fixture between said first and second registration cavities.
113. A method, as claimed in Claim 93, wherein: said mounting step comprises: disposing said first blade handle on an upper surface of said first blade; executing a first moving step comprising moving said first blade handle relative to said first blade after said disposing step; and terminating said first moving step upon registering said first blade handle to said first blade.
114. A method, as claimed in Claim 113, wherein: said disposing step comprises moving said first blade handle in a first direction toward said first blade, and wherein said first moving step comprises moving said blade handle in a second direction that is at least generally peφendicular to said first direction.
115. A method, as claimed in Claim 113, wherein: said first moving step comprises moving said first blade handle at least generally away from said first cutting edge of said first blade.
116. A method, as claimed in Claim 113, wherein: said first moving step comprises moving said first blade handle in a direction that is at least generally parallel to said upper surface of said first blade.
117. A method, as claimed in Claim 113, wherein: said registering step comprises a first registrant of said first blade handle engaging a first registiation surface of said first blade.
118. A method, as claimed in Claim 113, further comprising the step of: securing said first blade handle to said first blade after said terminating step.
119. A method, as claimed in Claim 93, wherein: said wafer comprises a plurality of said first blades, wherein said method further comprises repeating both said maintaining and mounting steps for each of said plurality of said first blades. 120. A method, as claimed in Claim 93, further comprising the step of: removing said wafer from said first fixtore after said mounting step, wherein said first blade remains part of said wafer while said first blade handle is mounted on said first blade.
121. A method for mounting a blade handle on a blade, comprising the steps of: positioning a wafer on a first fixture, wherein said wafer comprises a first blade; mounting a first blade handle on said first blade while on said first fixture; and removing said wafer from said first fixture after said mounting step.
122. A method, as claimed in Claim 121, wherein: said positioning step comprises positioning said wafer in a recess formed on an upper surface of said first fixture.
123. A method, as claimed in Claim 122, wherein: a perimeter of said recess at least substantially approximates a perimeter of said wafer. 124. A method, as claimed in Claim 121, wherein: said wafer comprises a first score associated with said first blade, wherein said positioning step comprises supporting said wafer with said first fixture directly under said first score, wherein said first blade may be separated from said wafer utilizing said first score. 125. A method, as claimed in Claim 124, further comprising the step of: aligning said first score with a predetermined crystal plane of said wafer.
126. A method, as claimed in Claim 121, wherein: said wafer comprises a first score associated with said first blade, wherein said positioning step comprises supporting said wafer such that said mounting step does not result in any net moment about said first score, wherein said first blade may be separated from said wafer utilizing said first score.
127. A method, as claimed in Claim 121, wherein: said wafer comprises a first cantilever, wherein said first blade is disposed on an end of said first cantilever, wherein said positioning step comprises supporting said first cantilever with said first fixture. 128. A method, as claimed in Claim 127, wherein: said positioning step comprises inhibiting any deflection of said first cantilever during said mounting step.
129. A method, as claimed in Claim 121, further comprising the step of: biasing said wafer toward said first fixture. 130. A method, as claimed in Claim 129, wherein: said biasing step comprises using a vacuum.
131. A method, as claimed in Claim 121, further comprising the step of: retaining said wafer on said first fixture using a vacuum.
132. A method, as claimed in Claim 121, further comprising the step of: maintaining a first cutting edge of said first blade in spaced relation to said first fixtore.
133. A method, as claimed in Claim 132, wherein: said maintaining step comprises disposing said first cutting edge of said first blade above a first cutting edge cavity formed on an upper surface of said first fixture. 134. A method, as claimed in Claim 121, wherein: said mounting step comprises maintaining said first blade handle in spaced relation with an entirety of said first fixture.
135. A method, as claimed in Claim 121, wherein: said mounting step comprises applying an adhesive to at least one of said first blade handle and said first blade.
136. A method, as claimed in Claim 135, wherein: said adhesive is light curable, wherein said method further comprises disposing said first blade handle in a predetermined position relative to said first blade after said applying step, and thereafter exposing at least a portion of said adhesive to light to fix said first blade handle to said first blade.
137. A method, as claimed in Claim 121, wherein: said mounting step comprises disposing a first registiant extending from a lower surface of said first blade handle into a first registiation cavity accessible through an upper surface of said first blade.
138. A method, as claimed in Claim 137, wherein: said disposing step of said mounting step comprises maintaining said first registrant in spaced relation with said first fixture.
139. A method, as claimed in Claim 138, wherein: said maintaining step of said disposing step comprises aligning said first registrant of said first blade handle with a first registrant cavity formed on an upper surface of said first fixture.
140. A method, as claimed in Claim 121, wherein: said mounting step comprises disposing first and second registrants extending from a lower surface of said first blade handle into first and second registtation cavities accessible through an upper surface of said first blade.
141. A method, as claimed in Claim 140, wherein: said disposing step comprises supporting said first blade with said first fixture between said first and second registtation cavities. 142. A method, as claimed in Claim 121, wherein: said mounting step comprises: disposing said first blade handle on an upper surface of said first blade; executing a first moving step comprising moving said first blade handle relative to said first blade after said disposing step; and terminating said first moving step upon registering said first blade handle to said first blade.
143. A method, as claimed in Claim 142, wherein: said disposing step comprises moving said first blade handle in a first direction toward said first blade, and wherein said first moving step comprises moving said blade handle in a second direction that is at least generally peφendicular to said first direction.
144. A method, as claimed in Claim 142, wherein: said first moving step comprises moving said first blade handle at least generally away from a first cutting edge of said first blade.
145. A method, as claimed in Claim 142, wherein: said first moving step comprises moving said first blade handle in a direction that is at least generally parallel to said upper surface of said first blade.
146. A method, as claimed in Claim 142, wherein: said registering step comprises a first registrant of said first blade handle engaging a first registiation surface of said first blade.
147. A method, as claimed in Claim 142, further comprising the step of: securing said first blade handle to said first blade after said terminating step.
148. A method, as claimed in Claim 121, wherein: said wafer comprises a plurality of said first blades, wherein said method further comprises repeating said mounting step for each of said plurality of said first blades before any execution of said removing step.
149. A method for mounting a blade handle on a blade, comprising the steps of: disposing a first blade handle on an upper surface of a first blade; executing a first moving step comprising moving said first blade handle relative to said first blade after said disposing step; terminating said first moving step upon registering said first blade handle to said first blade; and securing said first blade handle to said first blade after said registering step. 150. A method, as claimed in Claim 149, wherein: said disposing step comprises moving said first blade handle in a first direction toward said first blade, and wherein said first moving step comprises moving said blade handle in a second direction that is at least generally peφendicular to said first direction.
151. A method, as claimed in Claim 149, wherein: said first moving step comprises moving said first blade handle at least generally away from a first cutting edge of said first blade.
152. A method, as claimed in Claim 149, wherein: said first moving step comprises moving said first blade handle in a direction that is at least generally parallel to said upper surface of said first blade. 153. A method, as claimed in Claim 149, wherein: said registering step comprises a first registrant of said first blade handle engaging a first registiation surface of said first blade.
154. A method, as claimed in Claim 149, wherein: said securing step comprises applying an adhesive to at least one of said first blade handle and said first blade before said disposing step, and curing said adhesive.
155. A method, as claimed in Claim 149, further comprising the step of: positioning a wafer on a first fixture, wherein said wafer comprises said first blade, and wherein each of said disposing step, said first moving step, said terminating step, and said securing step are executed with said wafer on said first fixture.
156. A method, as claimed in Claim 155, wherein: said positioning step comprises positioning said wafer in a recess formed on an upper surface of said first fixtore.
157. A method, as claimed in Claim 156, wherein: a perimeter of said recess at least substantially approximates a perimeter of said wafer.
158. A method, as claimed in Claim 155, further comprising the step of: biasing said wafer toward said first fixture.
159. A method, as claimed in Claim 158, further comprising the step of: said biasing step comprises using a vacuum.
160. A method, as claimed in Claim 155, further comprising the step of: retaining said wafer on said first fixture using a vacuum.
161. A method, as claimed in Claim 155, wherein: said wafer comprises a plurality of said first blades, wherein said method further comprises repeating said disposing step, said first moving step, said terminating step, and said securing step for each of said plurality of said first blades while said wafer is on said first fixtore.
162. A method, as claimed in Claim 155, further comprising the step of: removing said wafer from said first fixture after said securing step, wherein said first blade remains part of said wafer while said first blade handle is mounted on said first blade.
163. A method for separating a blade from a wafer, comprising the steps of: positioning a wafer on a first fixture, wherein said wafer comprises a first blade; maintaining a first cutting edge of said first blade in spaced relation to said first fixture; and separating said first blade from a remainder of said wafer with said wafer on said first fixture.
164. A method, as claimed in Claim 163, wherein: said positioning step comprises positioning said wafer in a recess formed on an upper surface of said first fixtore.
165. A method, as claimed in Claim 164, wherein: a perimeter of said recess at least substantially approximates a perimeter of said wafer.
166. A method, as claimed in Claim 163, wherein: said wafer comprises a lower surface, wherein said positioning step comprises disposing less than an entirety of said lower surface of said wafer in contact with said first fixture. 167. A method, as claimed in Claim 163, further comprising the step of: biasing said wafer toward said first fixture.
168. A method, as claimed in Claim 167, wherein: said biasing step comprises using a vacuum.
169. A method, as claimed in Claim 163, further comprising the step of: retaining said wafer on said first fixture using a vacuum.
170. A method, as claimed in Claim 163, wherein: said positioning step comprises disposing an entirety of said first blade in spaced relation with said first fixture.
171. A method, as claimed in Claim 163, wherein: said positioning step comprises suspending said first blade above said first fixture.
172. A method, as claimed in Claim 171, wherein: said wafer comprises a first cantilever, wherein said first blade is disposed on an end of said first cantilever, wherein said positioning step comprises supporting at least a portion of said first cantilever with said first fixture. 173. A method, as claimed in Claim 171, wherein: said wafer further comprises a first blade support tab, wherein said first blade is disposed on an end of said first blade support tab, wherein said positioning step comprises supporting at least a portion of said first blade support tab with said first fixture.
174. A method, as claimed in Claim 163, wherein: said maintaining step comprises disposing said first cutting edge of said first blade above a first cutting edge cavity formed on an upper surface of said first fixture.
175. A method, as claimed in Claim 163, wherein: said maintaining step is executed throughout an entirety of both said positioning and separating steps. 176. A method, as claimed in Claim 163, wherein: said separating step comprises fracturing said wafer.
177. A method, as claimed in Claim 163, wherein: said separating step is executed at least substantially along a line that is at least substantially parallel with said first cutting edge.
178. A method, as claimed in Claim 163, wherein: said wafer comprises a first score associated with said first blade, wherein said separating step comprises fracturing said wafer at least substantially along said first score.
179. A method, as claimed in Claim 178, wherein: said positioning step comprises supporting said wafer proximate to said first score, while an entirety of said first blade is disposed in spaced relation to said first fixture.
180. A method, as claimed in Claim 163, wherein: said separating step comprises deflecting said first blade in a direction of said first fixture. 181. A method, as claimed in Claim 163, wherein: said separating step is executed with a first handle mounted on said first blade.
182. A method, as claimed in Claim 181, wherein: said separating step comprises applying a force on said first handle that is at least generally directed toward said first fixture. 183. A method, as claimed in Claim 163, wherein: said separating step comprises applying a force directly on said first blade that is at least generally directed toward said first fixture.
184. A method, as claimed in Claim 163, wherein: said separating step is completed before any portion of said first blade contacts said first fixture.
185. A method, as claimed in Claim 163, further comprising the steps of: disposing said first blade on said first fixture after said separating step; and executing said maintaining step throughout said separating step, after said separating step and before said disposing step, and throughout said disposing step.
186. A method, as claimed in Claim 163, wherein: said separating step comprises executing a first moving step, wherein said method further comprises the step of executing a second moving step, wherein said first moving step comprises moving said first cutting edge of said first blade at least generally toward said first fixture without having said first cutting edge contact said first fixture, and wherein said second moving step comprises moving said first cutting edge of said first blade at least generally away from said first fixture before said first moving step causes said first cutting edge to contact said first fixture.
187. A method, as claimed in Claim 163, further comprising the steps of: moving said first blade into contact with said first fixture after said separating step, and then pivoting said first blade to direct said first cutting edge of said first blade at least generally away from said first fixture.
188. A method, as claimed in Claim 163, further comprising the step of: disposing a lower surface of said first blade against a first surface of said first fixture after said separating step such that a rear edge of said first blade is disposed at a lower elevation relative to said first cutting edge, wherein said first surface is both inclined and planar.
189. A method, as claimed in Claim 188, further comprising the step of: retaining said first blade against said first surface.
190. A method, as claimed in Claim 189, wherein: said retaining step comprises using a vacuum. 191. A method, as claimed in Claim 163, wherein: said wafer comprises a plurality of said first blades, wherein said method further comprises repeating both said maintaining and separating steps for each of said plurality of said first blades, and thereafter removing said wafer from said first fixtore.
192. A method for separating a blade from a wafer, comprising the steps of: positioning a wafer on a first fixture, wherein said wafer comprises a first blade; suspending said first blade above said first fixtore; and separating said first blade from a remainder of said wafer while said wafer is on said first fixture. 193. A method, as claimed in Claim 192, wherein: said positioning step comprises positioning said wafer in a recess formed on an upper surface of said first fixtore.
194. A method, as claimed in Claim 193, wherein: a perimeter of said recess at least substantially approximates a perimeter of said wafer.
195. A method, as claimed in Claim 192, wherein: said wafer comprises a lower surface, wherein said positioning step comprises disposing less than an entirety of said lower surface of said wafer in contact with said first fixture.
196. A method, as claimed in Claim 192, further comprising the step of: biasing said wafer toward said first fixture.
197. A method, as claimed in Claim 196, wherein: said biasing step comprises using a vacuum. 198. A method, as claimed in Claim 192, further comprising the step of: retaining said wafer on said first fixture using a vacuum.
199. A method, as claimed in Claim 192, wherein: said wafer comprises a first cantilever, wherein said first blade is disposed on an end of said first cantilever, wherein said positioning step comprises supporting at least a portion of said first cantilever with said first fixture.
200. A method, as claimed in Claim 192, wherein: said wafer further comprises a first blade support tab, wherein said first blade is disposed on an end of said first blade support tab, wherein said positioning step comprises supporting at least a portion of said first blade support tab with said first fixture. 201. A method, as claimed in Claim 192, wherein: said suspending step comprises disposing a first cutting edge of said first blade above a first cutting edge cavity formed on an upper surface of said first fixture. 202. A method, as claimed in Claim 192, wherein: said separating step comprises fracturing said wafer. 203. A method, as claimed in Claim 192, wherein: said separating step is executed at least substantially along a line that is at least substantially parallel with said first cutting edge.
204. A method, as claimed in Claim 192, wherem: said wafer comprises a first score associated with said first blade, wherein said separating step comprises fracturing said wafer at least substantially along said first score.
205. A method, as claimed in Claim 204, wherein: said positioning step comprises supporting said wafer proximate to said first score, while an entirety of said first blade is disposed in spaced relation to said first fixture.
206. A method, as claimed in Claim 192, wherein: said separating step comprises deflecting said first blade in a direction of said first fixture.
207. A method, as claimed in Claim 192, wherein: said separating step is executed with a first handle mounted on said first blade.
208. A method, as claimed in Claim 207, wherein: said separating step comprises applying a force on said first handle that is at least generally directed toward said first fixture.
209. A method, as claimed in Claim 192, wherein: said separating step comprises applying a force directly on said first blade that is at least generally directed toward said first fixture.
210. A method, as claimed in Claim 192, wherein: said separating step is completed before any portion of said first blade contacts said first fixture. 211. A method, as claimed in Claim 192, further comprising the steps of: disposing said first blade on said first fixtore after said separating step; and maintaining a first cutting edge of said first blade in spaced relation to said first fixture throughout said separating step, after said separating step, before said disposing step, and throughout said disposing step.
212. A method, as claimed in Claim 192, wherein: said separating step comprises executing a first moving step, wherein said method further comprises the step of executing a second moving step, wherein said first moving step comprises moving a first cutting edge of said first blade al least generally toward said first fixture without having said first cutting edge contact said first fixture, and wherein said second moving step comprises moving said first cutting edge of said first blade at least generally away from said first fixture before said first moving step causes said first cutting edge to contact said first fixture.
213. A method, as claimed in Claim 192, further comprising the steps of: moving said first blade into contact with said first fixture after said separating step, and then pivoting said first blade to direct a first cutting edge of said first blade at least generally away from said first fixture.
214. A method, as claimed in Claim 192, further comprising the steps of: disposing a lower surface of said first blade against a first surface of said first fixture after said separating step such that a rear edge of said first blade is disposed at a lower elevation relative to a first cutting edge of said first blade that is opposite said rear edge, wherein said first surface is both inclined and planar.
215. A method, as claimed in Claim 192, further comprising the step of: retaining said first blade against said first surface.
216. A method, as claimed in Claim 215, wherein: said retaining step comprises using a vacuum. 217. A method, as claimed in Claim 192, wherein: said wafer comprises a plurality of said first blades, wherein said method further comprises repeating both said maintaining and separating steps for each of said plurality of said first blades, and thereafter removing said wafer from said first fixture.
218. A method for assembling a cutting tool, comprising the steps of: executing a first positioning step comprising positioning a wafer on a first fixture, wherein said wafer comprises a first blade; mounting a first blade handle on said first blade while said wafer is on said first fixtore; removing said wafer from said first fixture after said mounting step; executing a second positioning step comprising positioning said wafer on a second fixture; separating said first blade from a remainder of said wafer while said wafer is on said second fixture, wherein said separating step is executed after said mounting step.
219. A method, as claimed in Claim 218, wherein: said first positioning step comprises positioning said wafer in a first recess formed on an upper surface of said first fixture, and wherein said second positioning step comprises positioning said wafer in a second recess formed on an upper surface of said second fixture.
220. A method, as claimed in Claim 219, wherein: a perimeter of both said first and second recesses at least substantially approximates a perimeter of said wafer.
221. A method, as claimed in Claim 218, wherein: said wafer comprises a lower surface, wherein each of said first and second positioning steps comprises disposing less than an entirety of said lower surface of said wafer in contact with said first and second fixtures, respectively.
222. A method, as claimed in Claim 218, further comprising the step of: biasing said wafer toward said first fixture when said wafer is on said first fixture, and biasing said wafer toward said second fixture when said wafer is on said second fixtore.
223. A method, as claimed in Claim 222, wherein: each said biasing step comprises using a vacuum.
224. A method, as claimed in Claim 218, further comprising the steps of: retaining said wafer on said first fixture using a vacuum, and retaining said wafer on said second fixture using a vacuum.
225. A method, as claimed in Claim 218, further comprising the step of: maintaining a first cutting edge of said first blade in spaced relation to said first fixtore. 226. A method, as claimed in Claim 225, wherein: said maintaining step comprises disposing said first cutting edge of said first blade above a first cutting edge cavity formed on an upper surface of said first fixture. 227. A method, as claimed in Claim 225, wherein: said maintaining step is executed throughout said mounting step. 228. A method, as claimed in Claim 218, wherein: said wafer comprises a first score associated with said first blade, wherein said first positioning step comprises supporting said wafer with said first fixture directly under said first score, wherein said separating step utilizes said first score.
229. A method, as claimed in Claim 228, further comprising the step of: aligning said first score with a predetermined crystal plane of said wafer.
230. A method, as claimed in Claim 218, wherein: said wafer comprises a first score associated with said first blade, wherein said first positioning step comprises supporting said wafer such that said mounting step does not result in any net moment about said first score. 231. A method, as claimed in Claim 218, wherein: said wafer comprises a first cantilever, wherein said first blade is disposed on an end of said first cantilever, wherein said first positioning step comprises supporting said first cantilever with said first fixture.
232. A method, as claimed in Claim 231, wherein: said first positioning step comprises inhibiting any deflection of said first cantilever during said mounting step.
233. A method, as claimed in Claim 218, wherein: said mounting step comprises maintaining said first blade handle in spaced relation with an entirety of said first fixture.
234. A method, as claimed in Claim 218, wherein: said mounting step comprises applying an adhesive to at least one of said first blade handle and said first blade.
235. A method, as claimed in Claim 234, wherein: said adhesive is light curable, wherein said method further comprises disposing said first blade handle in a predetermined position relative to said first blade after said applying step, and thereafter exposing at least a portion of said adhesive to light to fix said first blade handle to said first blade.
236. A method, as claimed in Claim 218, wherein: said mounting step comprises disposing a first registrant extending from a lower surface of said first blade handle into a first registtation cavity accessible through an upper surface of said first blade.
237. A method, as claimed in Claim 236, wherein: said disposing step comprises maintaining said first registtant in spaced relation with said first fixture.
238. A method, as claimed in Claim 236, wherein: said disposing step comprises directing said first registtant of said first blade handle toward a first registrant cavity formed on an upper surface of said first fixture that is aligned with said first registrant. 239. A method, as claimed in Claim 218, wherein: said mounting step comprises disposing first and second registrants extending from a lower surface of said first blade handle into first and second registiation cavities accessible through an upper surface of said first blade.
240. A method, as claimed in Claim 239, wherein: said disposing step comprises supporting said first blade with said first fixture between said first and second registration cavities.
241. A method, as claimed in Claim 218, wherein: said mounting step comprises: disposing said first blade handle on an upper surface of said first blade; executing a first moving step comprising moving said first blade handle relative to said first blade after said disposing step; and terminating said first moving step upon registering said first blade handle to said first blade.
242. A method, as claimed in Claim 241, wherein: said disposing step comprises moving said first blade handle in a first direction toward said first blade, and wherein said first moving step comprises moving said blade handle in a second direction that is at least generally peφendicular to said first direction. 243. A method, as claimed in Claim 241, wherein: said first moving step comprises moving said first blade handle at least generally away from said first cutting edge of said first blade.
244. A method, as claimed in Claim 241, wherein: said first moving step comprises moving said first blade handle in a direction that is at least generally parallel to said upper surface of said first blade.
245. A method, as claimed in Claim 241, wherein: said registering step comprises a first registiant of said first blade handle engaging a first registration surface of said first blade.
246. A method, as claimed in Claim 241, further comprising the step of: securing said first blade handle to said first blade after said terminating step.
247. A method, as claimed in Claim 218, wherein: said wafer comprises a plurality of said first blades, wherein said method further comprises repeating said mounting step for each of said plurality of said first blades before said removing step. 248. A method, as claimed in Claim 218, further comprising the step of: maintaining a first cutting edge of said first blade in spaced relation to said second fixture.
249. A method, as claimed in Claim 248, wherein: said maintaining step comprises disposing said first cutting edge of said first blade above a first cutting edge cavity formed on an upper surface of said second fixture.
250. A method, as claimed in Claim 248, further comprising the step of: seating said first blade on said second fixture after said separating step, wherein said maintaining step is executed throughout an entirety of said separating step, from an end of said separating step to a start of said seating step, and throughout an entirety of said seating step.
251. A method, as claimed in Claim 248, further comprising the step of: executing a second maintaining step comprising maintaining said first cutting edge of said first blade in spaced relation to said first fixture.
252. A method, as claimed in Claim 251, wherein: said second maintaining step comprises disposing said first cutting edge of said first blade above a first cutting edge cavity formed on an upper surface of said first fixture. 253. A method, as claimed in Claim 251, wherein: said second maintaining step is executed throughout both said mounting step, wherein said first cutting edge never contacts either said first fixture or said second fixture.
254. A method, as claimed in Claim 218, further comprising the steps of: maintaining a first cutting edge of said first blade in spaced relation to said first fixture throughout said mounting step; and maintaining said first cutting edge of said first blade in spaced relation to said second fixture both throughout and after said separating step. 255. A method, as claimed in Claim 218, further comprising the steps of: seating said first blade on said second fixture after said separating step; and maintaining a first cutting edge of said first blade in spaced relation to said second fixture throughout said separating step, from an end of said separating step to a start of said seating step, and throughout an entirety of said seating step.
256. A method, as claimed in Claim 218, wherein: said second positioning step comprises disposing an entirety of said first blade in spaced relation with said second fixture.
257. A method, as claimed in Claim 218, wherein: said second positioning step comprises suspending said first blade above said second fixture.
258. A method, as claimed in Claim 257, wherein: said wafer comprises a first cantilever, wherein said first blade is disposed on an end of said first cantilever, wherein said second positioning step comprises supporting at least a portion of said first cantilever with said second fixture.
259. A method, as claimed in Claim 257, wherein: said wafer further comprises a first blade support tab, wherein said first blade is disposed on an end of said first blade support tab, wherein said second positioning step
comprises supporting at least a portion of said first blade support tab with said second fixture.
260. A method, as claimed in Claim 218, wherein: said separating step comprises fracturing said wafer. 261. A method, as claimed in Claim 218, wherein: said separating step is executed at least substantially along a line that is at least substantially parallel with said first cutting edge.
262. A method, as claimed in Claim 218, wherein: said wafer comprises a first score associated with said first blade, wherein said separating step comprises fracturing said wafer at least substantially along said first score.
263. A method, as claimed in Claim 262, wherein: said second positioning step comprises supporting said wafer proximate to said first score, while an entirety of said first blade is disposed in spaced relation to said second fixture. 264. A method, as claimed in Claim 218, wherein: said separating step comprises deflecting said first blade in a direction of said second fixture.
265. A method, as claimed in Claim 218, wherein: said separating step is executed with a first handle mounted on said first blade. 266. A method, as claimed in Claim 265, wherein: said separating step comprises applying a force on said first handle that is at least generally directed toward said first fixture.
267. A method, as claimed in Claim 218, wherein: said separating step comprises applying a force directly on said first blade that is at least generally directed toward said first fixture.
268. A method, as claimed in Claim 218, wherein: said separating step is completed before any portion of said first blade contacts said second fixture.
269. A method, as claimed in Claim 218, wherein: said separating step comprises executing a first moving step, wherein said method further comprises the step of executing a second moving step, wherein said first moving step comprises moving a first cutting edge of said first blade at least generally toward said second fixture without having said first cutting edge actually contact said second fixture, and wherein said second moving step comprises moving said first cutting edge of said
first blade at least generally away from said second fixture before said first moving step causes said first cutting edge to contact said second fixture.
270. A method, as claimed in Claim 218, further comprising the steps of: moving said first blade into contact with said second fixture after said separating step, and then pivoting said first blade to direct a first cutting edge of said first blade at least generally away from said second fixture.
271. A method, as claimed in Claim 218, further comprising the step of: disposing a lower surface of said first blade against a first surface of said second fixture after said separating step such that a rear edge of said first blade is disposed at a lower elevation relative to a first cutting edge of said first blade, wherein said first surface is both inclined and planar.
272. A method, as claimed in Claim 271, further comprising the step of: retaining said first blade against said first surface. 273. A method, as claimed in Claim 272, wherein: said retaining step comprises using a vacuum.
27 . A method, as claimed in Claim 218, wherein: said wafer comprises a plurality of said first blades, wherein said method further comprises repeating said separating step for each of said plurality of said first blades, and thereafter removing said wafer from said second fixture.
275. A method, as claimed in Claim 218, wherein said wafer comprises a plurality of said first blades, wherein said method further comprises the steps of: repeating said mounting step for each of said plurality of said first blades before said removing step; repeating said separating step for each of said plurality of said first blades; and removing said wafer from said second fixture after every said first blade has been separated from said wafer.
276. A cutting tool, comprising: a blade body comprising first and second oppositely disposed major surfaces, a first cutting edge surface disposed at an angle relative to at least said first major surface, and a first cutting edge defined at least in part by said first cutting edge surface, wherein said first major surface is defined by a first set of 3 Miller indices, and wherein at least one individual Miller index of said first set has an absolute value greater than 3.
277. A cutting tool, as claimed in Claim 276, wherein: said blade body is of a material selected from the group consisting of ceramic, silicon, and quartz.
278. A cutting tool, as claimed in Claim 276, wherein: said blade body is a single crystal material.
279. A cutting tool, as claimed in Claim 276, wherein: said second major surface is also defined by said first set of 3 Miller indices.
280. A cutting tool, as claimed in Claim 276, wherein: said first cutting edge surface is aligned with a predetermined crystallographic plane.
281. A cutting tool, as claimed in Claim 276, wherein: said first cutting edge surface is an etched surface.
282. A cutting tool, as claimed in Claim 281, wherein: said first cutting edge surface is aligned with a predetermined crystallographic plane.
283. A cutting tool, as claimed in Claim 276, wherein: said first cutting edge surface is oriented other than peφendicular to said first major surface.
284. A cutting tool, as claimed in Claim 276, wherein: said blade body further comprises a first registration surface spaced from said first cutting edge and parallel with said first cutting edge surface.
285. A cutting tool, as claimed in Claim 28 , wherein: said first registration surface is aligned with a predetermined crystallographic plane. 286. A cutting tool, as claimed in Claim 284, wherein: said first registtation surface is an etched surface.
287. A cutting tool, as claimed in Claim 286, wherein: said first registration surface is aligned with a predetermined crystallographic plane. 288. A cutting tool, as claimed in Claim 284, wherein: said first cutting edge surface and said first registtation surface are aligned with a common, predetermined crystallographic plane.
289. A cutting tool, as claimed in Claim 284, wherein: said first cutting edge surface and said first registiation surface are each an etched surface.
290. A cutting tool, as claimed in Claim 289, wherein: said first cutting edge surface and said first registiation surface are aligned with a common, predetermined crystallographic plane.
291. A cutting tool, as claimed in Claim 284, wherein: said first cutting edge surface extends from a first edge to said first cutting edge, wherein said first registration surface extends from a second edge to a third edge, wherein said first and second edges are disposed within a first reference plane, wherein said first cutting edge and said third edge are disposed within a second reference plane, and wherein said first and second reference planes are parallel.
292. A cutting tool, as claimed in Claim 284, further comprising: a blade handle interconnected with said blade body and comprising a first registrant that interfaces with at least part of said first registration surface.
293. A cutting tool, as claimed in Claim 292, wherein: an intersection between said first registration surface and said first major surface defines a first edge, wherein an intersection between said first registration surface and said second major surface defines a second edge, and wherein said blade holder interfaces with said first major surface.
294. A cutting tool, as claimed in Claim 293, wherein: said first registtant interfaces with said first registration surface closer to said second edge than said first edge.
295. A cutting tool, as claimed in Claim 293, wherein: said first registtant interfaces with said first registration surface along said second edge.
296. A cutting tool, as claimed in Claim 293, wherein: said first registiant extends below said second edge.
297. A cutting tool, as claimed in Claim 284, wherein: said blade body comprises a second registiation surface spaced from said first cutting edge and parallel with said first cutting edge surface.
298. A cutting tool, as claimed in Claim 297, wherein: said first and second registration surfaces are disposed within a common reference plane.
299. A cutting tool, as claimed in Claim 297, wherein: said first and second registration surfaces are aligned with a common, predetermined crystallographic plane.
300. A cutting tool, as claimed in Claim 297, wherein: said first and second registtation surface are each an etched surface.
301. A cutting tool, as claimed in Claim 300, wherein: said first and second registration surfaces are aligned with a common, predetermined crystallographic plane.
302. A cutting tool, as claimed in Claim 297, wherein: said first cutting edge surface, said first registiation surface, and said second registration surface are aligned with a common, predetermined crystallographic plane.
303. A cutting tool, as claimed in Claim 297, wherein: said first cutting edge surface, said first registration surface, and said second registiation surface are each an etched surface. 304. A cutting tool, as claimed in Claim 303, wherein: said first cutting edge surface, said first registtation surface, and said second registration surface are aligned with a common, predetermined crystallographic plane.
305. A cutting, tool, as claimed in Claim 297, further comprising: a blade handle interconnected with said blade body and comprising first and second registrants that interface with at least part of said first and second registtation surfaces, respectively.
306. A cutting tool, as claimed in Claim 305, wherein: said first and second registrants are positioned along a reference axis that is parallel with said first cutting edge. 307. A cutting tool, as claimed in Claim 305, wherein: said first and second registrants are equidistant from said first cutting edge.
308. A cutting tool, as claimed in Claim 276, wherein: said blade body further comprises a concave first registration cavity spaced from said first cutting edge and comprising first and second ends. 309. A cutting tool, as claimed in Claim 308, wherein: said first registiation cavity extends entirely through said blade body.
310. A cutting tool, as claimed in Claim 308, wherein: said first end of said first registration cavity is peφendicular to said first major surface, and wherein said first registration surface is disposed at an angle other than peφendicular relative to said first major surface. 311. A cutting, tool, as claimed in Claim 308, further comprising: a blade handle interconnected with said blade body and comprising a first registiant that interfaces with at least part of second end of said first registration cavity, wherein said first registiant is spaced from said first end of said first registtation cavity.
312. A cutting tool, as claimed in Claim 308, wherein: said blade body further comprises a concave second registtation cavity spaced from said first cutting edge and comprising third and fourth ends.
313. A cutting, tool, as claimed in Claim 312, further comprising: a blade handle interconnected with said blade body and comprising first and second registtants that interface with at least part of second end of said first registration cavity and at least part of said fourth end of said second registtation cavity, wherein said first registrant is spaced from said first end of said first registration cavity, and wherein said second registrant is spaced from said third end of said second registration cavity.
314. A method for fabricating a blade from a substtate, comprising the steps of: executing a first etching step comprising etching said substrate to define a first cutting edge surface for a first blade; and executing a second etching step comprising etching said substrate to define a first score, wherein said first blade may be separated from said substrate at least substantially along said first score. 315. A method, as claimed in Claim 314, wherein: said substiate is ceramic.
316. A method, as claimed in Claim 314, wherein: said substiate is silicon.
317. A method, as claimed in Claim 314, wherein: said substtate is quartz.
318. A method, as claimed in Claim 314, wherein: said substrate is a single crystal material.
319. A method, as claimed in Claim 314, wherein: said first and second etching steps are simultaneously executed with a single etchant.
320. A method, as claimed in Claim 319, wherein: said single etchant is an anisotropic etchant.
321. A method, as claimed in Claim 314, wherein: said first and second etching steps are each a chemical etch.
322. A method, as claimed in Claim 314, further comprising the step of: defining a first cutting edge for said first blade using said first etching step, wherein said first cutting edge is parallel with a length dimension of said first score.
323. A method, as claimed in Claim 314, further comprising the step of: executing a third etching step comprising etching through said substrate to define a first portion of a perimeter of said first blade, and etching through said substrate to define a first blade support tab interconnecting said first blade with a remainder of said substrate, wherein said first score extends across at least a portion of said first blade support tab.
324. A method, as claimed in Claim 323, wherein: said first, second, and third etching steps are simultaneously executed with a single etchant. 325. A method, as claimed in Claim 323, wherein: said first score extends across only a portion of said first blade support tab.
326. A method, as claimed in Claim 323, wherein: said first score comprises first and second ends, wherein said first and second ends are spaced inwardly from first and second edges, respectively, of said first blade support tab.
327. A method, as claimed in Claim 323, wherein: said third etching step comprises etching through said substrate to define a pair of notches on a first perimeter wall of said first blade, wherein said first blade support tab extends between said pair of notches, and wherein said first score is located so that said pair of notches are disposed beyond said first score.
328. A method, as claimed in Claim 323, wherein: said second etching step comprises locating said first score at a minimum width location along said first blade support tab.
329. A method, as claimed in Claim 314, wherein: said second etching step comprises etching into said substtate a first amount that is within a range of about 2% to about 75% of a thickness of said substrate.
330. A method, as claimed in Claim 314, wherein: said second etching step comprises etching into said substtate a first amount that is within a range of about 2% to about 5% of a thickness of said substrate.
331. A method, as claimed in Claim 314, wherein: said second etching step comprises etching into said substtate a first amount that is within a range of about 10 microns to about 30 microns. 332. A method, as claimed in Claim 314, wherein: said second etching step comprises etching through only a portion of a thickness of said substrate.
333. A method, as claimed in Claim 314, wherein: said second etching step comprises etching said substrate to define first and second planar score surfaces that intersect along a first line.
334. A method, as claimed in Claim 332, wherein: said first line is aligned with a crystallographic plane of said substrate.
335. A method, as claimed in Claim 314, wherein: said second etching step comprises aligning said first score with a crystallographic plane of said substiate.
336. A method, as claimed in Claim 314, wherein: said first score comprises a first score surface that is parallel with said first cutting edge surface.
337. A method, as claimed in Claim 314, further comprising the steps of: forming a first masking layer on said substrate; and transferring a blade mask onto said first masking layer, wherein each of said first and second etching steps are executed through openings in said first masking layer in accordance with said blade mask. 338. A method, as claimed in Claim 337, wherein: a first portion of said transferring step is selected from the group consisting of photomasking, masking, photolithography, and microphotolithography said first masking layer in accordance with said blade mask, and wherein a second portion of said transferring step is selected from the group consisting of wet chemical etching, plasma
etching, reactive ion etching, and ion beam milling said first masking layer in accordance with said blade mask.
339. A method for fabricating a blade from a substrate, comprising the steps of: executing a first etch comprising etching through a substrate to define a first perimeter portion of a first blade, wherein said first perimeter portion extends between first and second ends such that said first blade remains part of said substrate between said first and second ends; executing a second etch comprising etching through said substtate to define a first blade support tab, wherein a first free end of said first blade support tab merges into said first blade between said first and second ends; and executing a third etch comprising etching a first score across at least a portion of said first blade support tab.
340. A method, as claimed in Claim 339, wherein: said substrate is ceramic.
341. A method, as claimed in Claim 339, wherein: said substrate is silicon.
342. A method, as claimed in Claim 339, wherein: said substrate is quartz. 343. A method, as claimed in Claim 339, wherein: said substrate is a single crystal material.
344. A method, as claimed in Claim 339, wherein: said first, second, and third etches are simultaneously executed with a single etchant. 345. A method, as claimed in Claim 344, wherein: said single etchant is an anisotropic etchant.
346. A method, as claimed in Claim 339, wherein: said first, second, and third etches are each a chemical etch.
347. A method, as claimed in Claim 339, wherein: said first etch comprises defining a first cutting edge for said first blade, wherein said first cutting edge is parallel with a length dimension of said first score.
348. A method, as claimed in Claim 339, wherein: said first score extends across only a portion of said first blade support tab.
349. A method, as claimed in Claim 339, wherein: said first score comprises first and second ends, wherein each of said first and second ends are spaced inwardly from first and second side edges of said first blade support tab. 350. A method, as claimed in Claim 339, wherein: said first etch comprises etching through said substrate to define a pair of notches on a first perimeter wall of said first blade, wherein said first blade support tab extends between said pair of notches, and wherein said first score is located so that said pair of notches are disposed beyond said first score. 351. A method, as claimed in Claim 339, wherein: said third etch comprises etching into said substtate a first amount that is within a range of about 2% to about 75% of a thickness of said substtate.
352. A method, as claimed in Claim 339, wherein: said third etch comprises etching into said substtate a first amount that is within a range of about 2% to about 5% of a thickness of said substrate.
353. A method, as claimed in Claim 339, wherein: said third etch comprises etching into said substrate a first amount that is within a range of about 10 microns to about 30 microns.
354. A method, as claimed in Claim 339, wherein: said third etch comprises etching through only a portion of a thickness of said substtate.
355. A method, as claimed in Claim 339, wherein: said third etch comprises etching said substtate to define first and second planar score surfaces that intersect along a first line. 356. A method, as claimed in Claim 355, wherein: said first line is aligned with a crystallographic plane of said substtate.
357. A method, as claimed in Claim 339, wherein: said third etch comprises aligning said first score with a crystallographic plane of said substrate. 358. A method, as claimed in Claim 339, wherein: said first score comprises a first score surface that is parallel with a first cutting edge surface of said first blade defined by said first etch.
359. A method, as claimed in Claim 339, wherein: said third etch comprises locating said first score at a minimum width location along said first blade support tab.
360. A method, as claimed in Claim 339, further comprising the steps of: forming a first masking layer on said substrate; and transferring a blade mask onto said first masking layer, wherein each of said first, second, and third etches are executed through openings in said first masking layer in accordance with said blade mask. 361. A method, as claimed in Claim 360, wherein: a first portion of said transfeπing step is selected from the group consisting of photomasking, masking, photolithography, and microphotolithography said first masking layer in accordance with said blade mask, and wherein a second portion of said transferring step is selected from the group consisting of wet chemical etching, plasma etching, reactive ion etching, and ion beam milling said first masking layer in accordance with said blade mask.
362. A method for fabricating a blade from a substrate, comprising the steps of: creating at least one opening that extends completely through said substrate, wherein said creating step comprises defining a first perimeter portion of a first blade, wherein said first perimeter portion extends between first and second ends such that said first blade remains part of said substrate between said first and second ends; and defining a first score having first and second ends, wherein each of said first and second ends are spaced from any said opening from said creating step. 363. A method, as claimed in Claim 362, wherein: said substiate is ceramic.
364. A method, as claimed in Claim 362, wherein: said substrate is silicon.
365. A method, as claimed in Claim 362, wherein: said substiate is quartz.
366. A method, as claimed in Claim 362, wherein: said substiate is a single crystal material.
367. A method, as claimed in Claim 362, wherein: said creating step comprises etching.
368. A method, as claimed in Claim 367, wherein: said etching step is an anisotropic etch.
369. A method, as claimed in Claim 362, wherein: said defining a first perimeter portion step comprises defining a first cutting edge, wherein said defining a first score step comprises disposing said first score in parallel relation with said first cutting edge.
370. A method, as claimed in Claim 362, wherein: said defining a first perimeter portion step comprises defining a planar first cutting edge surface, wherein said defining a first score step comprises defining a planar first score surface, wherein said first cutting edge surface and said first score surface are parallel.
371. A method, as claimed in Claim 362, wherein: said creating step further comprising defining a first blade support tab that interconnects said first blade with a remainder of said substtate, wherein said first score extends across at least a portion of said first blade support tab.
372. A method, as claimed in Claim 371, wherein: said first score extends across only a portion of said first blade support tab.
373. A method, as claimed in Claim 371, wherein: said first and second ends of said first score are spaced inwardly from first and second side edges, respectively, of said first blade support tab.
374. A method, as claimed in Claim 371, wherein: said defining a first perimeter portion step comprises defining a pair of notches on a first perimeter wall of said first blade, wherein said first blade support tab extends between said pair of notches, wherein said first score is located so that said pair of notches are disposed beyond said first score.
375. A method, as claimed in Claim 371, wherein: said defining a first score step comprises locating said first score at a minimum width location along said first blade support tab.
376. A method, as claimed in Claim 362, wherein: said defining a first score step comprises etching.
377. A method, as claimed in Claim 362, wherein: said defining a first score step comprises extending said first score to a depth within said substrate that is within a range of about 2% to about 75% of a thickness of said substtate.
378. A method, as claimed in Claim 362, wherein: said defining a first score step comprises extending said first score to a depth within said substtate that is within a range of about 2% to about 5% of a thickness of said substrate. 379. A method, as claimed in Claim 362, wherein: said defining a first score step comprises extending said first score to a depth within said substtate that is within a range of about 10 microns to about 30 microns.
380. A method, as claimed in Claim 362, wherein: said defining a first score step comprises extending said first score through only a portion of a thickness of said substrate.
381. A method, as claimed in Claim 362, wherein: said defining a first score step comprises defining first and second planar score surfaces that intersect along a first line.
382. A method, as claimed in Claim 381, wherein: said first line is aligned with a crystallographic plane of said substrate.
383. A method, as claimed in Claim 362, wherein: said defining a first score step comprises aligning said first score with a crystallographic plane of said substrate.
384. A method, as claimed in Claim 362, wherein: said creating step and said defining a first score step each comprise etching said substrate.
385. A method, as claimed in Claim 384, further comprising the steps of: forming a first masking layer on said substrate; and transferring a blade mask onto said first masking layer, wherein said etching step is executed through openings in said first masking layer in accordance with said blade mask.
386. A method, as claimed in Claim 385, wherein: a first portion of said transferring step is selected from the group consisting of photomasking, masking, photolithography, and microphotolithography said first masking layer in accordance with said blade mask, and wherein a second portion of said transferring step is selected from the group consisting of wet chemical etching, plasma etching, reactive ion etching, and ion beam milling said first masking layer in accordance with said blade mask.
387. A method for fabricating a blade from a substtate, comprising the steps of: creating at least one opening that extends completely through said substtate, wherein said creating step comprises defining a first perimeter portion of a first blade, wherein said first perimeter portion extends between first and second ends such that said first blade remains part of said substtate between said first and second ends; and defining a first score on said substtate that is associated with said first blade, wherein said defining a first score step comprises using a same technique as said creating step, and wherein said first blade may be separated from a remainder of said substtate using said first score.
388. A method for fabricating a blade from a substrate, comprising the steps of: creating at least one opening that extends completely through said substtate, wherein said creating step comprises defining a first perimeter portion of a first blade, wherein said first perimeter portion extends between first and second ends such that said first blade remains part of said substiate between said first and second ends; and defining a first score on said substrate that is associated with said first blade, wherein said defining a first score step is executed during said creating step, and wherein said first blade may be separated from a remainder of said substrate using said first score. 389. A method for fabricating a blade from a substiate, comprising the steps of: creating at least one opening that extends completely through said substtate, wherein said creating step comprises defining a first perimeter portion of a first blade, wherein said first perimeter portion extends between first and second ends such that said first blade remains part of said substtate between said first and second ends, wherein said first perimeter portion comprises a first cutting edge and an oppositely disposed rear end; and defining a first score on said substrate that is associated with said first blade, wherein said first score is located between a rearwardmost portion of said rear end and said first cutting edge, and wherein said first blade may be separated from a remainder of said substrate using said first score.
390. A cutting blade, comprising: a body, comprising: a first cutting edge;
a first perimeter wall comprising a notch, wherein a first perimeter surface of said notch is of a first texture and a second perimeter surface of said notch is of a second texture that is different than said first texture.
391. A cutting blade, as claimed in Claim 390, wherein: said body is formed from a material selected from the group consisting of single crystal silicon and single crystal quartz.
392. A cutting blade, as claimed in Claim 390, wherem: said body is formed from a single crystal material for which there is at least one crystal-plane selective etchant. 393. A cutting blade, as claimed in Claim 390, wherein: said first cutting edge defines a first end of said body, and wherein said first perimeter wall defines a second end of said first body that is opposite said first end.
394. A cutting blade, as claimed in Claim 390, wherein: said first cutting edge and said first perimeter surface of said notch are at least generally parallel.
395. A cutting blade, as claimed in Claim 390, wherein: said first cutting edge and said second perimeter surface of said notch are parallel.
396. A cutting blade, as claimed in Claim 390, wherein: said body comprises upper and lower surfaces, wherein each of said first and second perimeter surfaces of said notch are peφendicular to each of said upper and lower surfaces.
397. A cutting blade, as claimed in Claim 390, wherein: said first and second perimeter surfaces of said notch are each planar surfaces that are disposed within a common reference plane. 398. A cutting blade, as claimed in Claim 390, wherein: said first and second perimeter surfaces of said notch are each planar surfaces that are parallel to and offset from each other.
399. A cutting blade, as claimed in Claim 390, wherein: said second perimeter surface is offset from said first perimeter surface, wherein said second perimeter surface is an etched surface, and wherein said first perimeter surface is defined other than by an etch.
400. A cutting blade, as claimed in Claim 390, wherein: said second perimeter surface of said notch is an etched surface, and wherein said first perimeter surface of said notch is a fractured surface.
401. A cutting blade, as claimed in Claim 390, wherein: said body comprises upper and lower surfaces, wherein said first perimeter wall extends between said first and second primary surfaces, and wherein an entirety of a perimeter of said notch, including said second perimeter surface, is etched except for said first perimeter surface.
402. A cutting blade, as claimed in Claim 390, wherein: said body comprises upper and lower surfaces, wherein all surfaces of said body extending from said upper surface at least generally in a direction of said lower surface and vice versa, except for said first perimeter surface of said notch, are etched. 403. A cutting blade, as claimed in Claim 390, wherein: said body comprises upper and lower surfaces, wherein all surfaces of said body except said upper surface, said lower surface, and said first perimeter surface are etched. 404. A cutting blade, as claimed in Claim 390, wherein: said body comprises first and second primary surfaces, wherein said first perimeter wall extends between said first and second primary surfaces, wherein said second perimeter surface of said notch extends from said first primary surface toward said second primary surface and terminates prior to reaching said second primary surface, wherein a first part of said first perimeter surface of said notch extends from a lowest extreme of said second perimeter surface of said notch to said second primary surface. 405. A cutting blade, as claimed in Claim 404, wherein: a second part of said first perimeter surface of said notch extends from said first primary surface to said second primary surface, wherein a third part of said first perimeter surface of said notch also extends from said first primary surface to said second primary surface, and wherein said second perimeter surface is disposed between said second and third parts of said first perimeter surface of said notch.
406. A cutting blade, as claimed in Claim 405, wherein: said first perimeter surface of said notch is at least generally U-shaped in plan view.
407. A cutting blade, as claimed in Claim 390, wherein: said second perimeter surface of said notch is a first score surface of a first score used to separate said first blade from a remainder of a wafer from which said first blade was fabricated.
408. A cutting blade, as claimed in Claim 407, wherein: said body comprises upper and lower surfaces, wherein said first score surface is planar and peφendicular to each of said upper and lower surfaces.
409. A cutting blade, as claimed in Claim 390, wherein: said first perimeter wall comprises first and second sections that are laterally spaced and disposed on opposite sides of said notch, wherein a perimeter of said notch comprises said first and second perimeter surfaces, a third perimeter surface, and a fourth perimeter surface, wherein said third perimeter surface intersects with said first section of said first perimeter wall, wherein said fourth perimeter surface intersects with said second section of said first perimeter wall, and wherein an entirety of said first perimeter surface of said notch is recessed relative to said first and second sections of said first perimeter wall.
410. A cutting blade, as claimed in Claim 409, wherein: said second perimeter surface of said notch is an etched surface, and wherein said first perimeter surface of said notch is a fractured surface.
411. A cutting blade, comprising: a body, comprising: upper and lower surfaces; a first cutting edge; a first perimeter wall extending between said upper and lower surfaces and comprising a notch, wherein an entirety of a perimeter of said notch is etched except for a first perimeter surface.
412. A cutting blade wafer, comprising: a wafer comprising a frame; a first cutting blade comprising a first cutting edge; a first blade support tab interconnecting said frame of said wafer and said first cutting blade, wherein said first blade support tab comprises first and second sides that are laterally spaced; a first space disposed between said first side of said first blade support tab and a first portion of said first cutting blade; and a second space disposed between said second side of said first blade support tab and a second portion of said first cutting blade.
413. A cutting blade wafer, as claimed in Claim 412, wherein: said wafer comprises upper and lower surfaces, wherein said cutting blade wafer comprises a first perimeter opening extending from said upper surface to said lower surface and that extends about an entirety of a perimeter of said first cutting blade except for where said first cutting blade interfaces with said first blade support tab, wherein said first perimeter opening comprises said first and second spaces.
414. A cutting blade wafer, as claimed in Claim 412, further comprising: a first score extending across at least a portion of said first blade support tab in a direction progressing toward each of said first and second sides of said first blade support tab.
415. A cutting blade wafer, as claimed in Claim 414, wherein: said first score extends across only a portion of said first blade support tab.
416. A cutting blade wafer, as claimed in Claim 414, wherein: said first score comprises first and second ends, wherein said first and second ends are spaced inwardly from first and second sides, respectively, of said first blade support tab.
417. A cutting blade wafer, as claimed in Claim 414, wherein: said first score has a depth that is within a range of about 2% to about 75% of a thickness of said wafer.
418. A cutting blade wafer, as claimed in Claim 414, wherein: said first score has a depth that is within a range of about 2% to about 5% of a thickness of said wafer.
419. A cutting blade wafer, as claimed in Claim 414, wherein: said first score has a depth that is within a range of about 10 microns to about 30 microns.
420. A cutting blade wafer, as claimed in Claim 414, wherein: said first score extends through only a portion of a thickness of said wafer.
421. A cutting blade wafer, as claimed in Claim 414, wherein: said first score comprises first and second planar score surfaces that intersect along a first line.
422. A cutting blade wafer, as claimed in Claim 421, wherein: said first line is aligned with a crystallographic plane of said wafer.
423. A cutting blade wafer, as claimed in Claim 414, wherein: at least a portion of said first score is aligned with a crystallographic plane of said wafer.
424. A cutting blade wafer, as claimed in Claim 414, wherem: said first cutting blade comprises a first, second, third, and fourth wall sections, wherein said first and second wall sections intersect, wherein said third and fourth wall sections intersect, wherein said second and fourth wall sections each define a portion of a boundary of said first and second spaces, respectively, wherein said first score is recessed relative to a reference plane that contacts at least a portion of each of said first and third wall sections.
425. A cutting blade wafer, as claimed in Claim 424, wherem: said first cutting blade further comprises fifth and sixth wall sections, wherein said fifth wall section is located between said second wall section of said cutting blade and said first side of said blade support tab and thereby also defines a portion of said boundary of said first space, wherein said sixth wall section is located between said fourth wall section of said cutting blade and said second side of said blade support tab and thereby also defines a portion of said boundary of said second space, and wherein said first score is recessed relative to said reference plane in a direction of said fifth and sixth wall sections. 426. A cutting blade wafer, as claimed in Claim 414, wherein: said first cutting blade comprises a first, second, third, and fourth wall sections, wherein said first and second wall sections intersect at a first location, wherein said third and fourth wall sections intersect at a second location, wherein said second and fourth wall sections each define a portion of a boundary of said first and second spaces, respectively, and at least generally face said first and second sides, respectively, of said first blade support tab, wherein said first and third wall sections fail to define any portion of said first and second spaces, wherein said first score is offset from a reference plane that extends through said first and second locations, wherein said offset is in a direction of where said first blade support tab merges with said first cutting blade. 427. A microkeratome cutting tool, comprising: a blade comprising first and second oppositely disposed major surfaces, a first cutting edge surface disposed at an angle relative to each of and extending between said first and second major surfaces, and a first cutting edge defined by an intersection of said first cutting edge surface and said first major surface; and
a blade handle mounted on said blade and comprising a lower surface, wherein said lower surface of said blade handle and part of said first major surface face each other, and wherein said blade handle is spaced back from said first cutting edge.
428. A microkeratome cutting tool, as claimed in Claim 427 wherein: said blade is a material selected from the group consisting of ceramic, silicon, and quartz.
429. A microkeratome cutting tool, as claimed in Claim 427, wherein: said blade is a single crystal material.
430. A microkeratome cutting tool, as claimed in Claim 427, wherein: said first and second major surfaces are planar and disposed in parallel relation.
431. A microkeratome cutting tool, as claimed in Claim 427, wherein: at least one of said first and second major surfaces are defined by a first set of 3
Miller indices, and wherein at least one individual Miller index of said first set has an absolute value greater than 3. 432. A microkeratome cutting tool, as claimed in Claim 431, wherein: each of said first and second major surfaces are defined by said first set of 3 Miller indices.
433. A microkeratome cutting tool, as claimed in Claim 427, wherein: said first cutting edge surface is aligned with a predetermined crystallographic plane.
434. A microkeratome cutting tool, as claimed in Claim 427, wherein: said first cutting edge surface is an etched surface.
435. A microkeratome cutting tool, as claimed in Claim 434, wherein: said first cutting edge surface is aligned with a predetermined crystallographic plane.
436. A microkeratome cutting tool, as claimed in Claim 427, wherein: said first cutting edge surface is oriented other than peφendicular to said first major surface.
437. A microkeratome cutting tool, as claimed in Claim 427, wherein: an angle between said first cutting edge surface and said first major surface is acute.
438. A microkeratome cutting tool, as claimed in Claim 427, wherein: said first cutting edge surface is planar.
439. A microkeratome cutting tool, as claimed in Claim 427, wherein: said blade further comprises a first registtation surface spaced from said first cutting edge, and wherein said blade handle comprises a first registtant that interfaces with at least part of said first registration surface. 440. A microkeratome cutting tool, as claimed in Claim 427, wherein: said blade further comprises a first registration surface spaced from said first cutting edge and parallel with said first cutting edge surface, and wherein said blade handle comprises a first registrant that interfaces with at least part of said first registration surface. 441. A microkeratome cutting tool, as claimed in Claim 440, wherein: said first cutting edge surface and said first registtation surface are aligned with a common, predetermined crystallographic plane.
442. A microkeratome cutting tool, as claimed in Claim 440, wherein: said first cutting edge surface and said first registtation surface are each an etched surface.
443. A microkeratome cutting tool, as claimed in Claim 442, wherein: said first cutting edge surface and said first registtation surface are aligned with a common, predetermined crystallographic plane.
444. A microkeratome cutting tool, as claimed in Claim 440, wherein: said first cutting edge surface extends from said first cutting edge to a first edge at said second major surface, wherein said first registration surface extends from a second edge at said first major surface to a third edge at said second major surface, wherein said first cutting edge and said second edge are disposed within a first reference plane, wherein said first and third edges are disposed within a second reference plane, and wherein said first and second reference planes are parallel.
445. A microkeratome cutting tool, as claimed in Claim 440, wherein: said first registrant interfaces with said first registtation surface only at an intersection between said first major surface and said first registtation surface.
446. A microkeratome cutting tool, as claimed in Claim 440, wherein: said blade comprises a second registration surface spaced from said first cutting edge and parallel with said first cutting edge surface, and wherein said blade handle further comprises a second registrant that interfaces with at least part of said second registiation surface.
447. A microkeratome cutting tool, as claimed in Claim 446, wherein: said first cutting edge surface, said first registration surface, and said second registration surface are aligned with a common, predetermined crystallographic plane.
448. A microkeratome cutting tool, as claimed in Claim 446, wherein: said first cutting edge surface, said first registration surface, and said second registration surface are each an etched surface.
449. A microkeratome cutting tool, as claimed in Claim 448, wherein: said first cutting edge surface, said first registiation surface, and said second registration surface are aligned with a common, predetermined crystallographic plane. 450. A microkeratome cutting tool, as claimed in Claim 446, wherein: said first and second registtation surfaces are disposed within a common reference plane.
451. A microkeratome cutting tool, as claimed in Claim 446, wherein: said first and second registrants are positioned along a reference axis that is parallel with said first cutting edge.
452. A microkeratome cutting tool, as claimed in Claim 446, wherein: said first and second registrants are equidistant from said first cutting edge.
453. A microkeratome cutting tool, as claimed in Claim 427, wherein: said blade further comprises a concave first registration cavity on said first major surface, spaced from said first cutting edge, and comprising first and second ends, and wherein said blade handle further comprises a first registiant extending within said first registtation cavity.
45 . A microkeratome cutting tool, as claimed in Claim 453, wherein: said first registtation cavity extends entirely through said blade from said first major surface to said second major surface.
455. A microkeratome cutting tool, as claimed in Claim 453, wherein: said first end of said first registration cavity is peφendicular to said first major surface, and wherein said second end is disposed at an angle other than peφendicular relative to said first major surface. 456. A microkeratome cutting, tool, as claimed in Claim 453, wherein: said first registiant that interfaces with at least part of second end of said first registration cavity, wherein said first registrant is spaced from said first end of said first registration cavity.
457. A microkeratome cutting, tool, as claimed in Claim 453, wherem: said first registtant engages said blade only at an intersection between said second end of said first registration cavity and said first major surface.
458. A microkeratome cutting tool, as claimed in Claim 453, wherein: said blade further comprises a concave second registtation cavity on said first major surface, spaced from said first cutting edge, and comprising third and fourth ends, and wherein said blade handle further comprises a second registrant extending within said second registration cavity.
459. A microkeratome cutting tool, as claimed in Claim 458, wherein: said first and second registtants are positioned along a reference axis that is parallel with said first cutting edge.
460. A microkeratome cutting tool, as claimed in Claim 458, wherein: said first and second registrants are equidistant from said first cutting edge.
461. A microkeratome cutting tool, as claimed in Claim 458, wherein: said first and second registration cavities each extend entirely through said blade from said first major surface to said second major surface.
462. A microkeratome cutting tool, as claimed in Claim 458, wherein: said first end of said first registration cavity and said third end of said second registration cavity are each peφendicular to said first major surface, and wherein said second end of said first registration cavity and said fourth end of said second registration cavity are each disposed at an angle other than peφendicular relative to said first major surface.
463. A microkeratome cutting, tool, as claimed in Claim 458, wherein: said first registtant interfaces with at least part of said second end of said first registtation cavity, wherein said first registrant is spaced from said first end of said first registration cavity, wherein said second registrant interfaces with at least part of said fourth end of said second registration cavity, and wherein said second registrant is spaced from said third end of said second registration cavity.
464. A microkeratome cutting, tool, as claimed in Claim 458, wherein: said first registrant engages said blade only at an intersection between said second end of said first registiation cavity and said first major surface, and wherein said second registrant engages said blade only at an intersection between said fourth end of said second registtation cavity and said first major surface.
465. A microkeratome cutting head assembly, comprising: an eye flap receptacle; and a blade comprising a first major surface, a second major surface that is disposed opposite of said first major surface, a first cutting edge surface that extends from said first major surface to said second major surface, and a first cutting edge defined by an intersection between said first major surface and said first cutting edge surface, wherein said first major surface is disposed above said second major surface.
466. A microkeratome cutting head assembly, as claimed in Claim 465, wherein: said first cutting edge surface at least generally faces a patient's eye when being cut by said microkeratome cutting head assembly.
467. A microkeratome cutting head assembly, as claimed in Claim 465, wherein: said first major surface is located generally between said second major surface and said eye flap receptacle; and said second major surface is located generally between said first major surface and a patient's eye when being cut by said microkeratome cutting head assembly.
468. A microkeratome cutting head assembly, as claimed in Claim 465, further comprising: a first blade support associated with said first major surface and comprising a first leading edge that is spaced back from said first cutting edge.
469. A microkeratome cutting head assembly, as claimed in Claim 468, wherein: said first leading edge of said first blade support is disposed no more than about 1 millimeter from said first cutting edge, measured in a dimension that is parallel with said first major surface.
470. A microkeratome cutting head assembly, as claimed in Claim 469, wherein: a blade angle measured between said first major surface and said first cutting edge surface is no more than about 35°.
471. A microkeratome cutting head assembly, as claimed in Claim 468, wherein: said first blade support defines a portion of said eye flap receptacle.
472. A microkeratome cutting head assembly, as claimed in Claim 468, wherein: said first blade support comprises means for directing a patient's eye flap being cut by said microkeratome cutting head assembly into said eye flap receptacle. 473. A microkeratome cutting head assembly, as claimed in Claim 468, wherein: said first cutting edge surface intersects with said second major surface at a first edge, wherein a reference plane, that is both peφendicular to said first major surface and that contains said first edge, intersects said first major surface at a first location. 474. A microkeratome cutting head assembly, as claimed in Claim 473, wherein: said first leading edge of said first blade support is located between said first cutting edge and said first location in a dimension that is parallel with said first major surface. 475. A microkeratome cutting head assembly, as claimed in Claim 473, wherein: said first leading edge of said first blade support is disposed closer to said first cutting edge than said first location is to said first cutting edge in a dimension that is parallel with said first major surface. 476. A microkeratome cutting head assembly, as claimed in Claim 473, wherein: said first cutting edge of said blade and said first edge of said blade are separated by a first distance measured along a first axis, wherein said first cutting edge of said blade and said first leading edge of said first blade support are separated by a second distance measured along a second axis that is parallel with said first axis, and wherein said second distance is less than said first distance.
477. A microkeratome cutting head assembly, as claimed in Claim 476, wherein: said first and second axes are peφendicular to said first cutting edge. 478. A microkeratome cutting head assembly, as claimed in Claim 468, further comprising: a second blade support that is associated with said second major surface of said blade.
479. A microkeratome cutting head assembly, as claimed in Claim 478, wherein: said second blade support comprises a second leading edge that is spaced back from said first cutting edge, wherein said first leading edge of said first blade support is closer to said first cutting edge than said second leading edge of said second blade support is to said first cutting edge in a dimension that is parallel with said first major surface.
480. A microkeratome cutting head assembly, as claimed in Claim 465, wherein: an underside of an eye flap being cut by said microkeratome cutting head assembly interfaces with part of said first major surface and not said first cutting edge surface.
481. A microkeratome cutting head assembly, as claimed in Claim 465, wherein: a blade angle measured between said first major surface and said first cutting edge surface is no more than about 35°.
482. A microkeratome cutting head assembly, comprising: an eye flap receptacle; a blade comprising a first major surface, a second major surface that is disposed opposite of said first major surface, a first cutting edge, and a first cutting edge surface that extends from said first cutting edge to said second major surface; and a first blade support associated with said first major surface and comprising a first leading edge that is spaced back from said first cutting edge, wherein said first cutting edge surface intersects with said second major surface at a first edge, wherein a first reference plane that is peφendicular to said first major surface and that contains said first edge intersects with a second reference plane that contains said first major surface at a first location, wherein said first leading edge is disposed somewhere between said first location and said first cutting edge in a dimension that is parallel with said first major surface. 483. A microkeratome cutting head assembly, as claimed in Claim 482, wherein: said first cutting edge surface at least generally faces a patient's eye when being cut by said microkeratome cutting head assembly.
484. A microkeratome cutting head assembly, as claimed in Claim 482, wherein: said first major surface is located generally between said second major surface and said eye flap receptacle; and said second major surface is located generally between said first major surface and a patient's eye when being cut by said microkeratome cutting head assembly.
485. A microkeratome cutting head assembly, as claimed in Claim 482, wherein: a blade angle associated with said first cutting edge is no more than about 35°. 486. A microkeratome cutting head assembly, as claimed in Claim 482, wherein: said first cutting edge surface extends from said first major surface to said second major surface, and wherein said first cutting edge is defined by an intersection between said first major surface and said first cutting edge surface. 487. A microkeratome cutting head assembly, as claimed in Claim 482, wherein: said first leading edge of said first blade support is disposed no more than about 1 millimeter from said first cutting edge, measured in a dimension that is parallel with said first major surface. 488. A microkeratome cutting head assembly, as claimed in Claim 487, wherein: a blade angle associated with said first cutting edge is no more than about 35°.
489. A microkeratome cutting head assembly, as claimed in Claim 482, wherein: said first blade support defines a portion of said eye flap receptacle.
490. A microkeratome cutting head assembly, as claimed in Claim 482, wherein: said first blade support comprises means for directing a patient's eye flap being cut by said microkeratome cutting head assembly into said eye flap receptacle. 491. A microkeratome cutting head assembly, as claimed in Claim 482, wherein: said first leading edge of said first blade support is disposed closer to said first cutting edge than said first location is to said first cutting edge in a dimension that is parallel with said first major surface.
492. A microkeratome cutting head assembly, as claimed in Claim 482, wherein: said first cutting edge of said blade and said first edge of said blade are separated by a first distance measured along a first axis, wherein said first cutting edge of said blade and said first leading edge of said first blade support are separated by a second distance measured along a second axis that is parallel with said first axis, and wherein said second distance is less than said first distance.
493. A microkeratome cutting head assembly, as claimed in Claim 492, wherein: said first and second axes are peφendicular to said first cutting edge.
494. A microkeratome cutting head assembly, as claimed in Claim 482, further comprising: a second blade support that is associated with said second major surface of said blade. 495. A microkeratome cutting head assembly, as claimed in Claim 494, wherein: said second blade support comprises a second leading edge that is spaced back from said first cutting edge, wherein said first leading edge of said first blade support is closer to said first cutting edge than said second leading edge of said second blade support is to said first cutting edge in a dimension that is parallel with said first major surface.
496. A microkeratome cutting head assembly, as claimed in Claim 482, wherein: an underside of an eye flap being cut by said microkeratome cutting head assembly interfaces with part of said first major surface and not said first cutting edge surface.
497. A microkeratome cutting head assembly, comprising: an eye flap receptacle; a blade comprising a first major surface, a second major surface that is disposed opposite of said first major surface, and a first cutting edge; and an upper blade support associated with said first major surface of said blade and comprising a first leading edge that is spaced back from said first cutting edge; a lower blade support associated with said second major surface of said blade and comprising a second leading edge that is spaced back from said first cutting edge,
wherein said first leading edge of said upper blade support is closer to said first cutting edge of said blade than said second leading edge of said lower blade support.