Abstract: There is provided a disk drive that includes a base, a limiting member, an actuator, and a latch. The actuator includes an actuator catch with a catch path. The latch contacts the limiting member with the latch in an open position. The latch is biased to rotate to a defeat position. An arresting portion is in the catch path with the latch in a closed position. The arresting portion is not in the catch path with the latch in the open position, and not in the catch path with the latch in the defeat position. A crash stop portion contacts the actuator with the latch in the closed position and with the actuator in a stop position. The crash stop portion does not contact the actuator with the latch in the defeat position. Also provided is a method of reworking a disk drive having the latch.

Abstract: A system is disclosed for maintaining proper alignment of a hard disk micro-actuator and magnetic head with respect to a drive arm's suspension during the curing process of the bonding agent used in their coupling. Embodiments may include a system to couple an actuator element to a suspension element comprising: a shim element to be plated at a first location between an actuator element and a suspension element to maintain a relative orientation of the actuator element with respect to the suspension element during a curing process of a bonding agent at a second location between said actuator element and said suspension element.

Abstract: A method of coupling a voice coil motor to a bowl-type base plate of a hard disk drive is described for a hard disk drive including a voice coil motor having a coil coupled to a rear end portion of an actuator arm, an upper yoke and a lower yoke provided at upper and lower portions of the coil respectively, a bowl-type base plate having a plurality of flattened structures for fastening the lower yoke in a position relative to the bowl-type base plate and a countersink formed in the lower yoke.

Abstract: A suspension load beam used for attachment to a slider assembly and an actuation arm in a disc drive for data storage has a rigid middle beam section comprising a rigid bottom layer, a rigid top layer and a composite core layer sandwiched between the bottom layer and the top layer. A method for fabricating a vibration resistant mechanical member used a disc drive subject to high frequency motion operations is also disclosed. The method involves making an integral laminate structure and fabricating the mechanical member from the integral laminate structure. The integral laminate structure has a rigid bottom layer, a composite core layer on top of the rigid bottom layer, and a rigid top layer on top of the core layer so that the composite core layer is sandwiched between the rigid bottom layer and the rigid top layer.

Abstract: A method for forming rails on the beam region of a disk drive head suspension. Rails are formed on a first portion of the beam region while supporting the beam region at a first location. Rails are formed on a second portion of the beam region while supporting the beam region at a second location that is different than the first location.

Abstract: When crimping suspensions to carriage arms using a metal ball by applying ultrasonic vibration to a crimping tool, the suspensions can be crimped to the carriage arms without causing deformation to the suspensions and the like. A method of assembling a carriage assembly aligns attachment holes provided in front ends of carriage arms and crimping portions provided on suspensions to set the suspensions on the carriage arms and then presses a ball through crimping holes provided in the crimping portions while applying ultrasonic vibration to the crimping tool to crimp the suspensions to the carriage arms. When doing so, a ball, such as a ball whose surface has been subjected to a dimpling process, for which a load that acts on the ball when the ball passes through the crimping holes is low compared to a spherical ball is used to crimp the suspensions to the carriage arms.

Abstract: Embodiments of the present invention pertain to method for manufacturing a shock absorber that allows a disk drive to move with respect to the chassis of a computer system. In one embodiment, a flexure is formed that is capable of being coupled to an assembly joint. An assembly joint is formed so that the assembly joint is capable of being coupled to the flexure and the chassis of a computer system. A shock absorber is created by coupling the flexure to the assembly joint. The shock absorber has a form that can be used to flexibly couple the disk drive's enclosure with the computer system's chassis without requiring an increase in size of the chassis.

Abstract: Certain example embodiments relate to a method for bonding slider row bars for a photolithography process. A holding device having a sticky surface is formed. A plurality of slider row bars is provided, with each having a first surface for forming an air bearing surface and a second surface opposite the first surface. The slider row bars are secured to the holding device with their first surfaces facing the sticky surface so that the first surfaces of the slider row bars are aligned each other. The slider row bars are bonded together by an encapsulating glue. A carrier is provided, and the carrier is bonded to the second surfaces of the slider row bars. The holding device is removed. The example embodiments also can be used to manufacture sliders.

Abstract: A method for de-tabbing a dielectric tab extending between and bonded to first and second stainless steel portions of a disk drive head suspension component. Exemplary first and second stainless steel portions are a flexure base region and a flexure tongue. The method includes applying laser energy to the dielectric tab. The laser energy is characterized by one or more parameters, e.g., a pulse width and/or an energy density, causing de-bonding of the dielectric tab from the first and second stainless steel portions.

Abstract: A method for bonding slider row bars for photolithography process, includes steps of: providing a first carrier plate having a sticky surface; providing slider row bars each having a first surface for forming ABS and an opposite second surface, and securing each slider row bar to the first carrier plate with its first surface facing the sticky surface; providing an encapsulation glue and dispensing it to the second surfaces and gaps between the slider row bars; providing a second carrier plate and attaching it to the second surfaces through the encapsulation glue; irradiating the first carrier plate and the encapsulation glue with ultraviolet light such that the first carrier plate is removed from the slider row bars, and the encapsulation glue is cured to bond the slider row bars with the second carrier plate together.

Abstract: A method for loading single head in a hard disk drive includes the following steps: mounting a head assembly (30) in a baseplate (10) of a hard disk drive, the head assembly comprising an actuator arm (32), a suspension (34) and a HGA, the baseplate engaging a motor (110) and the HGA is positioned close to the motor; biasing the suspension by a mounting tool (50) from the original position, the mounting tool comprising a cantilever arm (52), a pressing head (54) and a supporting rod (56), wherein, the mounting tool rotates to the suspension and gets down to press the suspension; mounting a disk (90) on the motor in the baseplate; and releasing the pressing head from the suspension, loading the HGA of the head assembly to a parking zone of the disk.

Abstract: There are provided a magnetic element capable of enhancing magnetic permeability of a magnetic member, improving a direct current superposition characteristic, and improving production efficiency and a method of manufacturing the magnetic element. The magnetic element includes a coil (30) formed of a conductor having an insulating film, a first core member (20) constituted of insulative soft magnetic ferrite and covering the coil (30), and a second core member (50) having soft magnetic metal powder as material and surrounded by the first core member (20). Furthermore, the magnetic element includes a third core member (40) which has soft magnetic metal powder as material and a higher filling ratio of the soft magnetic metal powder than the second core member 50 and is surrounded by the first core member (20).

Abstract: A method of assembling a carriage assembly is disclosed. The method is are capable of suppressing fluctuation in the crimped (deformed) states of spacer portions when suspensions are attached to carriage arms. The method aligns fitting holes 10a provided in carriage arms 10 with spacer holes 12b of suspensions 12. Then the method passes a ball 20 with a diameter equal to or greater than an inner diameter of the spacer holes 12b through the spacer holes 12b to crimp edge portions of the spacer holes 12b in spacer portions 12a and thereby attach the suspensions 12 to the carriage arms 10. While the ball 20 is being pressed and sandwiched from both sides of the spacer holes 12b by two pressure-applying members 40a, 40b an ultrasonic vibration is applied to the two pressure-applying members 40a, 40b, the two pressure applying members 40a, 40b are moved so as to pass the ball 20 through the spacer holes 12b.

Abstract: A method for dynamic electrical testing of head gimbal assemblies may include initiating an automated continuous process that includes selecting an unmounted head gimbal assembly; aligning the unmounted head gimbal assembly; loading the unmounted head gimbal assembly to a disc; and testing the unmounted head gimbal assembly.

Abstract: A method for mounting a head slider of the type having terminal pads to a wireless disk drive head suspension flexure including a slider mounting region, lead contact pads, and a deflectable and resilient slider engagement member for releasably mounting a head slider to the slider mounting region. The method includes engaging and deflecting the slider engagement member and positioning the head slider onto the slider mounting region and between the lead contact pads and the slider engagement member while the slider engagement member is deflected. The method further includes disengaging the slider engagement member and causing the slider engagement member to force the head slider into frictional engagement with the lead contact pads and the slider engagement member with the lead contact pads in mechanical and electrical contact with the head slider terminal pads.

Abstract: A robotic tool for assembling a portion of a disk drive includes a movable end effector that includes a first portion and a second portion that is movable relative to the first portion. The first portion may be configured to engage the actuator assembly and the second portion may be configured to engage the flex circuit connector. A controller may be provided to control the movable end effector, causing the end effector to pick up the head stack assembly in a first configuration, move the second portion of the end effector relative to the first portion thereof so as to articulate the head stack assembly into a second configuration that is different than the first configuration, and place the head stack assembly into the base.

Abstract: In certain example embodiments, a shipping comb for assembling a disk drive is provided. The shipping comb has a comb block which includes a locking portion having a comb pin hole formed therein, at least one spacer, and a connecting beam to connect the locking portion and the at least one spacer. A comb pin is received in the comb pin hole of the locking portion. The comb pin includes at least two engaging portions. A controlling system has a comb latch selectively engagable with the at least two engaging portions so as to control the comb pin to move in the comb pin hole. In certain example embodiments, a method for assembling a disk drive using the shipping comb is provided.

Abstract: Embodiments of the invention relate to making reconnection when a soldered connection fails in a head/slider used in a magnetic disk drive. In one embodiment, a solder mass deposited on a slider pad of a head/slider is separated from a lead pad and a solder ball connection is yet to be made between the slider pad and the lead pad. A shaping tip is heated to a temperature near a melting point of a solder. The shaping tip is moved in parallel with a surface of the slider pad toward the side of the lead pad to soften the solder mass. The solder mass is thereafter irradiated with a laser beam so as to form a solder fillet, thereby making a soldered connection between the lead pad and the slider pad.

Abstract: Embodiments of the invention relate to techniques to remove a defective head gimbal assembly (HGA) from a head stack assembly and replace the defective HGA with a good one without allowing any good HGAs to be damaged. In one embodiment, a volatile alcohol solvent is moved by gravity from a holder included in a reworking tool provided for a reworking jig to a shearing edge of a cartridge type edge mounted in the holder. The alcohol solvent is thereby deposited on the shearing edge in a drop-like shape through surface tension. The cartridge type edge is made to slide on a surface of an actuator arm and is inserted in a gap between contacting surfaces of a mount plate and the actuator arm. This assigns the drop-like alcohol solvent a function as a lubricant. Possible vibration can therefore be prevented from being transmitted through a carriage to other HGAs.

Abstract: A method for adjusting a performance parameter of a head suspension for positioning a read/write head in a disk drive. The suspension includes a beam and flexible element for carrying a read/write head extending from the beam. The flexible element has one or more adjustment portions. The beam has one or more openings adjacent to the adjustment portions of the flexible element to provide access to the adjustment portions through the beam. The method comprises acting upon one or more adjustment portions of the flexible element through one or more of the openings in the beam to change a performance parameter of the head suspension. A laser beam is used to irradiate the adjustment portions of the flexible element in one embodiment of the invention.

Abstract: A method is presented for repairing damaged photomasks for electronic component fabrication processes, particularly for fabrication of the ABS of a disk drive slider. The method includes applying an overcoat of material having index of fraction which is close to the index of refraction of the photoresist material of the damaged photomask to produce a non-scattering boundary surface. The overcoat material preferably includes an overcoat base material which is a polymer having an index of refraction which is in the range of plus or minus 0.1 from the index of refraction of said photoresist material.

Abstract: A head suspension for supporting a head slider over a storage media in a dynamic storage device is provided with a head suspension component having a spring metal layer, an electrically conductive layer and a dielectric layer interposed between the metal layer and the electrically conductive layer. A plurality of electrically conductive traces with bond pads are formed in the electrically conductive layer. A feature datum is also formed in the electrically conductive layer on a detachable carrier strip. The feature datum defines a first edge in the electrically conductive layer parallel to an edge of the bond pads.

Abstract: A method of making a slider includes the steps of laminating the bottom-facing surface of a third layer to the upper-facing surface of a fourth layer, laminating the bottom-facing surface of a second layer to the upper-facing surface of the third layer in a heat-compression mold, heat-pressing the combined second, third and fourth layers in the mold to form a desired shape, and heat pressing a first layer on top of the second layer inside the mold.

Abstract: To improve the quality of the products that are manufactured by soldering, through enabling highly reliable soldering while suppressing damages to the bonding targets caused due to the soldering. Provided is a soldering method for bonding each of bonding pads formed in respective bonding targets with solder. The method comprises: a bonding target placing step for placing each of bonding targets to a bonding position; a soldering step for placing solder between each of the bonding pads formed in each of the bonding targets, and for performing soldering by irradiating a heating beam to the solder; and a bonding target heating step for heating at least one of the bonding targets, which is executed before the soldering step and/or simultaneously with the soldering step.

Abstract: A head actuator assembly of a disk device has a suspension which supports a head, an arm which supports the suspension and is rotatably supported by a bearing portion, signal wires which extend on the suspension and the arm and are connected electrically to the head, and a board unit. In manufacture, the signal wires are mounted on the suspension and the arm, and a connecting end portion of the board unit is connected to the signal wires mounted on the suspension and the arm. Thereafter, the head is mounted on the suspension and connected electrically to the signal wires.

Abstract: A limiter used to limit the motion of a ring gimbal with attached slider relative to a load beam within a head suspension assembly of a disk drive. The ring gimbal includes a flexible substrate supporting at least one electrical lead and a limiter assembly joined to a portion of the flexible substrate. The ring gimbal also includes a tongue portion disposed within a substantially ring-like portion. The limiter is attached to a first surface of the tongue portion. The gimbal may further include a slider attached to a second surface of the tongue portion, wherein the second surface is opposite the first surface of the tongue portion.

Abstract: Provided is a method of manufacturing a magnetic head with which bonding of a slider and a suspension can be performed by taking an ABS pattern, which determines flying characteristics, as a reference, with no special fabrication required on the slider or the suspension. The method relates to a method of manufacturing a magnetic head for attaching a slider, on which an air bearing surface (ABS) is formed, to a suspension. A surface of the slider on which the ABS is formed is photographed, and the ABS and an engraved region formed within the ABS are identified from the photographed image. Then, a reference that serves as a guide in attaching the suspension is computed, and the slider is attached to the suspension based on the reference. It thus becomes possible for positive pressure and negative pressure that occur in the ABS to be well balanced centered about the suspension, making it possible to stabilize flying attitude and electrical characteristics.

Abstract: A disk drive head stack assembly (66) of a configuration that facilitates the assembly thereof is disclosed. One or more head/arm assemblies (74) are mounted on a pivot bearing (118). This pivot bearing (118) includes a tapered section (126). Each head/arm assembly (74) may be mounted on the pivot bearing (118). Thereafter, a retainer ring (102) may be advanced relative to the pivot bearing (118). Advancement of the retainer ring (102) along the tapered section (126) expands the retainer ring (102) so that the same may be disposed within a retainer ring slot (130) of the pivot bearing (118). Each head/arm assembly (74) is maintained between this retainer ring (102) and a flange (134) of the pivot bearing (118).

Abstract: A method of bonding flying leads produces reliable bonds between the flying leads and substrate pads and can efficiently bond a plurality of flying leads and a plurality of substrate pads using a bonding tool. Flying leads are respectively aligned with a plurality of substrate pads disposed in parallel and a bonding tool applies ultrasonic vibration to the flying leads to bond the respective substrate pads and the flying leads. Bonding is carried out using a bonding tool in which (at least one contact member) a plurality of contact members that contact(s) the flying leads and apply (applies) the ultrasonic vibration thereto are (is) rotatably supported.

Abstract: A system and method for the production level screening of low flying magnetic heads in the manufacture of disk drive head disk assemblies (HDAs) is disclosed. A test disk is provided and has a plurality of bumps extending from at least one surface thereof. The test disk is rotated to fly a head of a head gimbal assembly selected from the group adjacent the surface of the test disk. An interaction of the head with one or more of the plurality of bumps may be sensed and the head gimbal assembly may be screened out from the group in response to the sensing of the interaction.

Abstract: Embodiments of the present invention provide a head gimbal assembly manufacturing method which can attach another magnetic head slider to a suspension to be reused without addition of solder. According to one embodiment of the present invention, a head gimbal assembly (HGA) is attached to a jig. Both sides of a portion close to the rear end of a magnetic head slider are gripped with hot tweezers heated at about 200° C. They are heated for about four seconds while applying force in a direction of peeling off the magnetic head slider from gimbals, thus removing the magnetic head slider from the gimbals. When another magnetic head slider is attached to the suspension, an adhesive adhered to the gimbals is removed and another adhesive is applied to the gimbals. The back of another magnetic head slider is pressed to the adhesive, whereby the magnetic head slider is fixed to the gimbals. Next, the solder fillet left on the gimbals is irradiated with laser beams to be melted and joined to an electric terminal.

Abstract: A method of manufacturing a cartridge assembly of a hard disk drive, including a step of forming a part of a wiring circuit into flying leads and a step of forming a coating layer on the respective opposite surfaces of the bonding surfaces of the flying leads, which will be connected to bonding terminals of a flexible printed circuit board. The method also includes a step of placing an ultrasonic tool in contact with the opposite surfaces of the flying leads via the coating layers, and applying ultrasonic vibration from the ultrasonic tool in a state where the flying leads are pressed onto the bonding terminals to ultrasonically bond the flying leads and the bonding terminals together. Additionally, the method includes a step of heating and melting the coating layers to smooth surfaces of the coating layers that have been roughened by contact with the ultrasonic tool during ultrasonic bonding.

Abstract: A disk drive unit includes a first cover having a first part of magnet component and a head stack assembly mounted on the first cover; and a second cover assembled with the first cover, which having a second part of magnet component, a spindle motor and at least one disks. The invention also discloses a ramp tool used for assembling the disk drive which has its disk and HSA assembled in two different halves, which includes a tool body; and a holding means extending from the tool body to hold a lift tab of a head stack assembly in a loading status. The invention also disclose a method of assembling such as disk drive unit.

Abstract: A method of manufacturing a magnetic core includes providing a substrate with magnetically permeable material that has a first region and a second region near the first region, providing support to maintain a juxtaposition between the first region and the second region, forming a slit through the magnetically permeable material between the first region and the second region, introducing a binding agent into the slit and removing the support; wherein the binding agent maintains the juxtaposition between the first region and the second region after the support is removed.

Abstract: A method for bonding slider row bars for photolithography process, includes steps of: providing a first carrier plate having a sticky surface; providing slider row bars each having a first surface for forming ABS and an opposite second surface, and securing each slider row bar to the first carrier plate with its first surface facing the sticky surface; providing an encapsulation glue and dispensing it to the second surfaces and gaps between the slider row bars; providing a second carrier plate and attaching it to the second surfaces through the encapsulation glue; irradiating the first carrier plate and the encapsulation glue with ultraviolet light such that the first carrier plate is removed from the slider row bars, and the encapsulation glue is cured to bond the slider row bars with the second carrier plate together.

Abstract: Embodiments include a method for forming a head suspension assembly. A spacer layer is formed in or on a silicon wafer. A transfer film including an opening defining the shape of a slider support membrane is provided, and the opening is filled with a resin material. The transfer film with the resin material therein is positioned over the silicon wafer so that at least a portion of the resin material is positioned adjacent to the spacer layer. The resin material is baked to form a glassy carbon material. The spacer layer is etched to form a trench in the silicon wafer adjacent to the glassy carbon material, and a slider is positioned on the glassy carbon material over the trench.

Abstract: A head stack assembly of a disk drive unit including a head arm assembly (HAA) having a head gimbal assembly, a drive arm to be connected with the head gimbal assembly; wherein the drive arm comprises a securing portion, a connection portion and a spacer connecting the securing portion with the connection portion. In the present invention, at least one undercut is formed on the spacer of the drive arm to strengthen the drive arm. The invention also discloses a method of manufacturing such a head stack assembly.

Abstract: A method of making a multi-piece head suspension for a rigid disk drive. The method includes providing a first layer including a mounting region with an integral boss tower attached to a stiffener by one or more positioning tabs; attaching a second layer including a spring region to an interface between the mounting region and the stiffener; attaching a flexure to the stiffener; and removing the positioning tabs. The flexure can optionally be a portion of the second layer.

Abstract: Methods for forming data storage media and the media formed thereby are disclosed herein. In one embodiment, the method for forming a data storage media, comprises: injection molding a substrate comprising surface features, wherein said surface features have greater than about 90% of a surface feature replication of an original master; and disposing a data layer over at least one surface of said substrate; wherein said data storage media has an axial displacement peak of less than about 500? under shock or vibration excitation.

Abstract: A system and method for an improved magnetic head arm assembly (HAA), reducing complexity of design and difficulty of manufacture, is disclosed.

Abstract: A simple method is provided for protecting slider mounted read/write transducers from electrostatic discharge damage during the manufacture of disk drives. The method involves placing a ball of conducting thermoplastic resin, such as a gold or silver epoxy, between the terminal pads of the transducer and using the ball to shunt the pads to read-head shields and the slider substrate and thence to ground. The epoxy ball is easily applied and easily removed and can be used at different stages in the manufacturing process.

Abstract: A suspension for use in a disk drive is disclosed. The suspension has a hinge and load beam which are separately formed and subsequently joined together. The load beam is formed from a material which has improved damping characteristics. The load beam additionally has ribs constructed in order to balance the mass of the suspension about the torsional rotation axis. The location of the torsional rotation axis can be designed to intersect the head gimbal pivot point.

Abstract: A manufacturing method of an HAA includes a step of fixing a first lead conductor member onto a suspension, a step of attaching a second lead conductor member to at least one actuator arm, a step of fixing the suspension onto the at least one actuator arm, a step of electrically connecting the first lead conductor member fixed on the suspension with the second lead conductor member attached on the at least one actuator arm, a step of, thereafter, fixing a head slider provided with at least one head element onto the suspension, and a step of electrically connecting the at least one head element with the first lead conductor member.

Abstract: A manufacturing method of a magnetic head device includes a preheating step of irradiating a laser beam to terminal pads of a magnetic head slider and to connection pads of a lead conductor member that is to be electrically connected to the magnetic head slider, a supply step of supplying conductive metal material for connecting the terminal pads and the connection pads during or after the preheating step, and a heating step of performing molten-metal connections between the terminal pads and the connection pads by irradiating a laser beam to the conductive metal material.

Abstract: An insulating sheet is manufactured by attaching a buffer layer and a resin film using an adhesive layer that is not adhesive at a normal ambient temperature. Since there is no need to use a release liner when manufacturing the insulating sheet, there is no release of a silicone component. Accordingly, when installing a hard disk printed wiring board, the printed wiring board and electronic circuits inside the hard disk will not be damaged by the released silicone.

Abstract: An actuator assembly for supporting a read/write device in an information storage device having an actuator arm having at least one tower protruding from a first surface of the actuator arm, a loadbeam having at least one tower receiving means for receiving the at least one tower, wherein the at least one tower is shaped to extend into the at least one tower receiving means when the loadbeam is joined with the actuator arm, and wherein the tower and tower receiving means are configured such that deforming the at least one tower when within the at least one tower receiving means provides a deformation interference between the at least one tower and the at least one tower receiving means that reduces movement of the tower receiving means relative to the tower.

Abstract: A fixture with a shaped molding may hold a first micro-actuator part and a second micro-actuator part in place for coupling while maintaining the structure of the first micro-actuator part. The first micro-actuator part and the second micro-actuator part may be a frame or a strip of piezoelectric material. A vacuum nozzle system embedded in the fixture may hold the first micro-actuator part in place. A mobile vacuum nozzle system may hold the second micro-actuator in place and positions the second micro-actuator part relative to the first micro-actuator part. A camera system may monitor the process. A dispense may apply epoxy between the first and second micro-actuator part. An ultraviolet source may provide ultraviolet radiation for curing.

Abstract: An integrated lead suspension includes a solder ball that is placed between a lead wiring pad provided on a flexure of the suspension, and a bonding pad provided on a slider of a head gimbal section. The lead wiring pad and bonding pad are soldered by melting the solder ball. As a result, there is provided a recessed section into which a solder ball is placed by way of surface raised sections, using gravitational force, in the vicinity of the center line of the surface of the lead wiring pad. In this way the position of the solder ball is not displaced from the center line when a bonding pad and lead wiring pad are connected by means of a solder ball.

Abstract: A system and method for an improved magnetic head arm assembly (HAA) is disclosed. The HAA includes three principal components, a head gimbal assembly (HGA), a flexible printed circuit (FPC) assembly, and an actuator coil assembly. The design allows for HAA rigidity, yet each of the components is designable and manufacturable independent of one another, in addition to other advantages over current methods.

Abstract: A contact magnetic transfer (CMT) master template is made by first adhering a plastic film to a first surface of a silicon wafer. A resist pattern is then formed on the polyimide film and the polyimide is reactive-ion-etched through the resist to form recesses. The resist is removed and a chemical-mechanical-polishing (CMP) stop layer is deposited over the non-recessed regions of the polyimide, and optionally into the bottoms of the recesses. A layer of magnetic material is then deposited over the polyimide film to fill the recesses. A CMP process is then performed to remove magnetic material above the recesses and above the non-recessed regions and continued until the CMP stop layer is reached. The resulting upper surface of the polyimide film is then a continuous planar film of magnetic islands and regions of CMP stop layer material that function as the nonmagnetic regions of the template.