Abstract: A process of forming a two-piece pole for an inductive write head involves first forming a first pole piece having a width between opposite side surfaces defining a gap width of a transducing gap at an air bearing surface of the head. The process next involves forming a second pole piece having a first region remote from the air bearing surface and a second region extending from the first region toward the air bearing surface. The first region is wider than the width of the first pole piece. The second pole piece is formed so that at least a portion of the second region is contiguous a portion of the first pole piece and so that no sharp external corners exist between the first pole tip piece and the second pole piece within a pole tip region of the head.

Abstract: The method of making a thin-film magnetic head in accordance with the present invention forms a cover layer on an insulating layer about a magnetoresistive film so as to eliminate a protrusion riding on the magnetoresistive film. Then, the protrusion can be eliminated by etching. The part of insulating layer clad with the cover layer is not etched. This can prevent short-circuit from occurring because of thinning the insulating layer.

Abstract: A spin valve sensor has a pinned layer structure that has a net positive stress induced uniaxial anisotropy that promotes a pinning of the pinned layer structure in a pinned direction for stabilizing the pinning of the pinned layer structure at high temperatures near to a blocking temperature of a pinning layer which is exchange coupled to the pinned layer.

Abstract: A spin valve sensor with a continuous junction is provided which has a sensor portion of a free layer longitudinally biased by first and second AFM biasing layers that are exchange coupled to first and second side portions of the free layer and a sensor portion of an AFM pinning layer that pins a sensor portion of a pinned layer perpendicular to the ABS in either a top spin valve or a bottom spin valve sensor.

Abstract: The present invention provides a method for improving the static attitude of a head suspension assembly by improving the manufacture of electrical interconnects by providing a laterally directed tension on the electrical interconnect during manufacture, thereby substantially inhibiting deformation of the gimbal region of the interconnect and the creation of non-planar slider standoffs.

Abstract: The thin-film magnetic head of the present invention is provided with an antiferromagnetic layer, a pinned layer whose direction of magnetization is fixed by exchange-coupling with the antiferromagnetic layer, a free layer whose direction of magnetization varies according to external magnetic field, an intermediate layer disposed between the pinned layer and free layer, and a pair of electrode layers for supplying a sense current in a layer thickness direction of the free layer. One electrode layer is connected to the pinned layer. Due to this configuration, a sense current flows through the free layer, the intermediate layer, and the pinned layer, but basically does not flow through the antiferromagnetic layer. As a consequence, the antiferromagnetic layer does not contribute to total resistance of the magnetoresistance element, allowing a high magnetoresistance ratio to be obtained.

Abstract: A method for manufacturing a magnetic recording head includes the steps of forming a first lifting layer and a second lifting layer on a bottom core layer, forming an inorganic insulating layer in a gap between the first lifting layer and the second lifting layer, forming a groove in the inorganic insulating layer to form a coil layer, and forming the coil layer in the groove and over the groove by plating.

Abstract: A method of manufacturing a combination type thin film magnetic head having an inductive type thin film magnetic head supported by a substrate including forming a first magnetic layer extending from an air bearing surface and forming an insulating layer on a surface of a portion of the first magnetic layer such that the insulating layer extends at least the air bearing surface and includes a -shaped cut-out portion.

Abstract: To provide a method of manufacturing a thin film magnetic head capable of realizing an accurate control of a pole width and a sufficient overwrite characteristic even when the pole width is narrowed. In a connecting portion of an intermediate portion and a tip portion in a top pole, a step face in a width direction of almost the right angle is provided. The step face has a first corner at an intersection portion between the step face and a side face in the tip portion. A positive photoresist is used for a photolithography process to form the top pole. A photomask used at the time of exposure includes a projection in a shape having an acute angle portion in a portion corresponding to the first corner in the top pole. Consequently, a wedge-shaped recess is formed in the first corner in the top pole. Thus, even when the throat height is changed, the recording track width is not changed and the recording track width can be prevented from being widened.

Abstract: The present invention provides an improved bias magnet-to-magnetoresistive element interface and method of fabrication. In a preferred embodiment, the wall/walls of an MR element opposing a bias layer are formed by over etching to provide vertical side walls without taper. In the preferred embodiment, a protective element is formed over the MR element to protect it during etch processes. In some embodiments, a filler layer is deposited prior to bias layer formation. In CIP embodiments, any portion of the filler layer forming on vertical side walls of the MR element is etched to provide an exposed side wall surface for contiguous bias layer formation. In CPP embodiments, the filler layer forms on a vertical back wall and electrically insulates the MR element from the bias layer.

Abstract: A magnetic head including a spin valve sensor having a sensor layer stack that includes a pinned magnetic layer, a spacer layer formed on the pinned magnetic layer, and a free magnetic layer formed on the spacer layer. In a preferred embodiment the spacer layer is comprised of CuOx. Plasma smoothing of the upper surface of the pinned magnetic layer is conducted prior to depositing the spacer layer, and a preferred plasma gas is a mixture of argon and oxygen.

Abstract: A horizontal combined head is provided which has both a thin film write and an MR read element located at an air bearing surface (ABS). The read element can be formed with a track width that is independent of the track width of the write element. The MR sensor or the read element is separated from one of the first and second pole pieces of the write element by an insulation layer. Accordingly, the shields for the read element remain more stable after a write operation. In one embodiment of the present invention a single stripe MR sensor is employed while in a second embodiment a dual stripe MR sensor is employed. A method of the invention includes forming the dual MR stripe in a single process step so that the dual MR stripes of the dual MR sensor are near identical for implementing near absolute common mode rejection of noise.

Abstract: A method of manufacturing a thin film magnetic head includes forming a recording gap layer of a non-alumina base nonmagnetic material on a lower magnetic pole layer, the lower magnetic pole layer being composed of materials that are milled at the same rate. An upper magnetic pole layer is formed on the recording gap layer, and a single piece of equipment is used to trim the lower magnetic pole layer and pattern the recording magnetic gap layer such that the lower magnetic pole layer has a width that is substantially the same as that of the upper magnetic pole layer. The recording gap layer and the upper and lower half-gap layers are then removed over a region of the underlying substrate. Prescribed areas of tan air-bearing surface (ABS) are then etched to form a slider shape having a protruding part and a depressed part, the ABS and the side surface having a common edge such that the depressed part along the common edge extends into, but not beyond, the region.

Abstract: The invention allows a thin-film magnetic head that meets specifications required by the customer to be provided in a short period of time and manufacturing costs to be reduced. A slider of a magnetic head of the invention comprises two thin-film magnetic head element portions formed near an end face orthogonal to the direction of air flow. On the end face four pad-shaped electrodes are provided for electrically connecting the two head element portions to an external device. The electrodes are selectively connected to one of the head element portions through four conductors.

Abstract: A method of manufacturing a thin-film magnetic head comprises the steps of forming a bottom pole layer, forming a gap layer, forming a top pole layer, and forming a thin-film coil. The thin-film coil is wound around the top pole layer in a helical manner. In the step of forming the bottom pole layer, the bottom pole layer is formed to include a first layer facing a portion of the thin-film coil, and a second layer that forms a pole portion and is connected to a surface of the first layer facing the top pole layer. In the step of forming the thin-film coil, a portion of the coil is disposed on a side of the second layer and another portion of the coil is disposed over the top pole layer via an insulating film.

Abstract: A head suspension or head suspension component for supporting a head slider over a rigid disk in a dynamic storage device and a method of manufacturing. The head suspension includes a head suspension component and a compliant locating feature formed within the head suspension component. The compliant locating feature includes a plurality of spring beam tabs defined by an aperture and positioned to extend toward an opening. The compliant feature is preferably configured to receive a tapered cylindrical pin through the opening for precisely locating the head suspension component relative to a desired reference while the spring beam tabs are engaged by the tapered pin. The head suspension component may include two or more compliant locating features, and the head suspension may include two or more components that each include one or more compliant locating features.

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: The present invention is directed towards increasing the conductivity of the electrical lead material in the read head portion of a magnetic head, such that thinner electrical leads can be fabricated while the current carrying capacity of the leads is maintained. This increase in electrical lead conductivity is accomplished by fabricating the electrical lead upon an epitaxially matched seed layer, such that the crystalline microstructure of the electrical lead material has fewer grain boundaries, whereby the electrical conductivity of the lead material is increased. In a preferred embodiment, the electrical lead material is comprised of Rh, which has an FCC crystal structure, and the seed layer is comprised of a metal, or metal alloy having a BCC crystal structure with unit cell lattice constant dimensions that satisfy the relationship that abcc is approximately equal to 0.816afcc. In various embodiments, the seed layer is comprised of VMo or VW.

Abstract: A triple antiparallel (AP) coupled free layer structure is located between first and second pinned layer structures in a dual spin valve sensor. The triple AP coupled free layer structure includes first, second and third antiparallel (AP) coupled ferromagnetic free layers and nonmagnetic first and second antiparallel (AP) coupling layers. The first AP coupling layer is located between and interfaces the first and second AP coupled free layers and the second AP coupling layer is located between and interfaces the second and third AP coupled free layers. Magnetic moments of the first and third AP coupled free layers are parallel with respect to one another and, because of a strong antiparallel coupling, the second AP coupled free layer pins magnetic moments of the first and third AP coupled free layers antiparallel thereto.

Abstract: A horizontal combined head is provided which has both a thin film write and an MR read element located at an air bearing surface (ABS). The read element can be formed with a track width that is independent of the track width of the write element. The MR sensor or the read element is separated from one of the first and second pole pieces of the write element by an insulation layer. Accordingly, the shields for the read element remain more stable after a write operation. In one embodiment of the present invention a single stripe MR sensor is employed while in a second embodiment a dual stripe MR sensor is employed. A method of the invention includes forming the dual MR stripe in a single process step so that the dual MR stripes of the dual MR sensor are near identical for implementing near absolute common mode rejection of noise.

Abstract: A thin film magnetic head is capable of reducing inductance by shortening a magnetic path, and also preventing a cavity from being formed in a coil insulating layer. The coil insulating layer is deposited on a lower core layer and at the rear of a recording portion, and a coil forming groove is formed in the coil insulating layer. Then, a coil layer is embedded in the coil forming groove. With this arrangement, bulges of the layers from an upper surface of the recording portion can be decreased so as to shorten a magnetic path.

Abstract: An object of the invention is to provide a thin film magnetic head which can exhibit a high-performance head characteristic without complicating the manufacturing procedure, and a method of manufacturing the same. A coil connection is integrated into one body and constituted part of the thin film coil. A connection middle pattern is provided on the coil connection at the time of forming a pole tip so that the position of the upper surface of the connection middle pattern becomes higher than that of the top pole tip. After the whole portion is covered by an insulating film, the connection middle pattern also can be exposed by polishing the surface of the insulating film until the top pole tip is exposed. Therefore, unlike the case where no connection middle pattern is provided, it is not necessary to have a step of forming an opening by partially removing part of the insulating film. As a result, the number of manufacturing steps can be reduced.

Abstract: At high frequencies, signal losses may occur in circuit designs employing magnetic isolators. Eddy current losses in the magnetic isolator substrate material are at least partially responsible for this signal loss. As the Eddy current losses may depend on the properties of the substrate, the type of substrate chosen for fabricating a magnetic isolator may be critical for reducing these losses. By fabricating the magnetic isolator on a high performance substrate, the Eddy current losses are reduced and the magnetic isolator provides better output signals at high frequencies.

Abstract: A magnetoresistive sensor for use in a data storage device has a recessed sensing element (magnetic tunnel junction, CPP spin valve, etc.) with an exchange biased sensing ferromagnetic (free) layer, and a flux guide that magnetically connects the sensing element to a sensing surface of the sensor. The free layer is selectively exchange biased by a layer of exchange bias material placed under non-active regions of the free layer that lie outside the sensing element and flux guide track widths. The flux guide is provided by extending the free layer from a forward edge of the sensing element to the sensor surface. Advantageously, the sensing element and the flux guide have equal track width so that magnetic flux directed from the flux guide into the sensing element is not diluted with consequent loss of sensitivity.

Abstract: A multi-track magnetoresistive (MR) tape head with precisely-aligned read/write (R/W) track-pairs and a method for fabrication on a monolithic substrate wherein a plurality of tape heads are fabricated from a single substrate wafer by using complete thin-film processing on both sides of the wafer. The recording elements are aligned with readers opposite writers on the other side, providing a method for fabricating a multi-track thin-film magnetoresistive tape head with precisely-aligned R/W track-pairs fabricated on a monolithic substrate. As used herein, the term monolithic denominates an undivided seamless piece. The wafer is built using modified standard thin-film processes for fabricating direct access storage device (DASD) heads and modified substrate lapping procedures. The gap-to-gap separation within each R/W track-pair is reduced to nearly the thickness of the substrate wafer, which is significantly less than conventional separations known in the art.

Abstract: A perpendicular recording head for use with magnetic storage media includes a flux focusing main pole. The main pole includes a layer of material having a high magnetic moment, and a second layer of material having a low magnetic moment. The low moment material is tapered towards the main pole's tip, so that all magnetic flux is channeled into the high moment material before writing to the magnetic storage medium.

Abstract: The object of the invention is to provide a thin film magnetic head and a method of manufacturing the same, which allow the magnetic pole width to be precisely controlled and a sufficient overwrite performance to be attained even in a case where the magnetic pole width is microfabricated. The coupling position where the intermediate portion and the tip of the top pole are coupled each other is located closer to the air bearing surface than the throat height 0 position (TH0 position) which is the reference point for determining the throat height TH. The tip of the top pole defines the write track width on a recording medium. At least the portion of the intermediate portion from the TH0 position to the rear edge portion of the tip has a width wider than that of the tip. The intermediate portion suppresses saturation of the magnetic flux before flowing into the tip of the top pole.

Abstract: Disclosed is a method of manufacturing a thin film magnetic head, which enables a magnetic pole portion to be formed with high precision in a short time. After forming a mask precursor pattern by patterning an alumina layer, the mask precursor pattern is subjected to an etching process of ion milling, thereby forming a first mask. The width of a portion in the first mask is narrower than the width of the minimum pattern which can be formed by a photolithography process. Consequently, by performing the etching process, the width of the portion of the first mask can be narrowed.

Abstract: A method for making a magnetic sensor for a disk drive read head, the method comprising the steps of depositing a magnetoresistive stack on a surface of a first layer of material, depositing a resist layer on a first portion of the magnetoresistive stack, removing a second portion of the magnetoresistive stack not covered by the resist layer, depositing a layer of additional material on the magnetoresistive stack, the resist material, and the surface of the first layer, removing the additional material from sidewalls of the resist material, and using a lift-off process to remove the resist material. Magnetic sensors made by the above process are also included.

Abstract: A method of making a magnetic head suspension assembly includes attaching a slider with a magnetic head to an intermediate flexible circuit. The attached combination is then inserted into a spin stand tester for the testing of electrical performance. If the attached combination fails the test, it is discarded, thereby avoiding the cost of discarding an entire head suspension assembly. On the other hand, if the attached combination passes the test, it is mounted to a load beam to form the head suspension assembly. Thereafter, a flex circuit can be attached to the load beam and intermediate flexible circuit to provide electrical connections to the magnetic head through the intermediate flexible circuit.

Abstract: The present invention provides a magnetoresistive element that can suppress the characteristic degradation even after high-temperature heat treatment, specifically at 400° C. to 450° C. This element is manufactured by a method that includes the following processes in the indicated order: a film formation process for forming at least a first ferromagnetic layer, a second ferromagnetic layer, and a non-magnetic layer on a substrate; a preheat process at 330° C. to 380° C. for not less than 60 minutes; and a heat treatment process at 400° C. to 450° C. This element has a resistance value that changes with a change in relative angle formed by the magnetization directions of the first ferromagnetic layer and the second ferromagnetic layer.

Abstract: A magnetoresistive sensor having a well defined track width and method of manufacture thereof.

Abstract: A spin valve sensor is provided with a negative ferromagnetic coupling field −HFC for properly biasing a free layer and a spin filter layer is employed between the free layer and a capping layer for increasing the magnetoresistive coefficient dr/R of the spin valve sensor. A top portion of the free layer is oxidized for improving the negative ferromagnetic coupling field −HFC when the spin filter layer is employed for increasing the magnetoresistive coefficient dr/R.

Abstract: A method of making a magnetic read/write head using a single lithographic step to define both a write coil and a pole tip structure. The use of a thin image resist layer over a hard reactive-ion etch mask and image transfer techniques allows very high resolution optical lithography which can accommodate formation of a very compact coil and pole structure. The use of a single high resolution lithography step on a planarized structure to define both a write pole tip and a write coil coplanar with the write pole tip avoids the problems of reflective notching associated with lithography to define the pole tip in the vicinity of non-planar features of the coil structure and also eliminates alignment inaccuracies inherent in separate lithography processes for the coil and pole.

Abstract: The invention provides a method of manufacturing a magnetic head slider and fixing a bar which improves fabrication accuracy without increasing manufacturing costs. After thin film magnetic head devices are formed on a wafer, the wafer is cut into bars each including two or more magnetic head sliders. The bars are carried and mounted onto a suction plater. A surface of each bar to be processed is brought into direct contact with a suction surface of the suction plate, and is positioned in a plane parallel to the suction surface. An adhesive is applied to the surface of a support substrate. The surfaces opposite to the surfaces to be processed are pressed against the adhesive. The adhesive is allowed to set. Adhesive thickness varies according to variations in thicknesses of the bars. Therefore, the surfaces of the bars to be processed can be kept aligned with a reference plane.

Abstract: The method of manufacturing a thin film magnetic head is capable of precisely forming a core section with preventing the variation of the write-core head caused by ion milling for removing an electric conductive film and capable of improving yield of products. The method of manufacturing a thin film magnetic head, in which a core section having prescribed write-core width is formed by applying ion milling to an upper magnetic pole and a lower magnetic pole, comprises the steps of examining the write-core width of the core section; covering a surface of the core section with a protection film except an electric conductive film for preventing electro static charge of a wafer; and removing the exposed electric conductive film by ion milling.

Abstract: This invention teaches a way for the shield to shield (S1-S2) distance of a magnetic read head to be reduced. The key feature is that the upper and lower dielectric layers D1 and D3, which are normally pure aluminum oxide, have each been replaced by a bilayer dielectric, which consists of aluminum oxide in contact with the shield layer followed by a layer of a high voltage breakdown material. For D1 this layer may be either tantalum oxide or tantalum nitride while for D3 our preferred material has been tantalum oxide. The addition of the two high breakdown layers allows the thickness of the upper and lower dielectric layers to be reduced without having to reduce the S2-S2 voltage difference.

Abstract: The present invention provides a non-actuatable, self-limiting wear contact pad slider and method for making the same. A protruding element surrounding the transducer is fabricated using a third etch step so that the protruding element has a height that is greater than or equal to the designed fly height of the aerodynamic lift surface minus the disk roughness.

Abstract: A magneto-resistive read head having a “parasitic shield” provides an alternative path for currents associated with sparkovers, thus preventing such currents from damaging the read head. The parasitic shield is provided in close proximity to a conventional magnetic shield. The electrical potential of parasitic shield is held essentially equal to the electrical potential of the sensor element. If charges accumulate on the conventional shield, current will flow to the parasitic shield at a lower potential than would be required for current to flow between the conventional shield and the sensor element. Alternatively, conductive spark gap devices are electrically coupled to sensor element leads and to each magnetic shield. Each spark gap device is brought within very close proximity of the substrate to provide an alternative path for charge that builds up between the sensor element and the substrate to be discharged.

Abstract: A method for making a thin-film magnetic head having a magnetoresistive effect element wherein an insulating layer is formed under an electrode layer of a magnetoresistive effect element with a lower gap layer interposed therebetween. As a result, the distance between the electrode layer and the lower shielding layer becomes longer, thus permitting maintenance of a satisfactory electrical insulation.

Abstract: A method of fabricating a magnetic transducer (head) according to the invention includes forming multilayered electrically conductive leads for the magnetic sensor which include a thin tantalum seed layer followed by a thin chromium seed layer which is followed by a thicker rhodium layer. The dual seed layer of the invention significantly improves the conductivity of the rhodium. The Ta/Cr/Rh leads can be used with hard bias structures formed on a PtMn layer without having increased resistance.

Abstract: A glide head for detecting asperities on a disc surface is provided. The glide head includes a glide slider which includes a glide slider body that has a leading edge, a trailing edge, and a bottom surface therebetween. The bottom surface is centered along a longitudinal axis that extends between the leading and trailing edges. An inside rail is disposed on the bottom surface on a first side of the longitudinal axis extends from the leading edge to the trailing edge. An outside rail is disposed on the bottom surface on a second side of the longitudinal axis. The outside rail also extends from the leading edge to the trailing edge. The inside and outside rails are substantially equidistant from the longitudinal axis at the bottom surface. The outside rail is positioned lower than the inside rail such that a bottom surface of the outside rail extends further from a point on the longitudinal axis on the trailing edge than does a bottom surface of the inside rail.

Abstract: A free layer for a spin valve sensor includes a cobalt iron (CoFe) film which has an easy axis oriented perpendicular to an air bearing surface (ABS) of a read head and a nickel iron (NiFe) film which has an easy axis oriented parallel to the ABS and parallel to the major planes of the thin film layers. In a further embodiment the free layer is annealed at a high temperature in the presence of a field which is oriented perpendicular to the ABS.

Abstract: Process for collective production of integrated magnetic heads with a supporting surface with a determined height. According to the invention the components of a board are thinned collectively be etching the board along area overlapping polar parts.

Abstract: (a) A method of manufacturing a magnetic head suspension includes a polyimide precursor layer 2 that is formed over a springy material layer 1, (b) a metal layer 3 for lines is formed over the polyimide precursor layer 2, (c) the metal layer 3 is patterned by the subtractive process to produce lines 4, (d) the polyimide precursor layer 2 is patterned by a photolithographic technique to give the configuration corresponding to a polyimide insulating base layer 5, (e) the patterned polyimide precursor layer 2 is imidated to produce the polyimide insulating base layer 5, and (f) a cover coat layer 6 is formed over the lines 4.

Abstract: The present invention relates to a dice system that is configured to manufacture disc drive heads from a substrate. The dice system includes a first dicing station that includes a plurality of processing modules. The dice system also includes a control module separate and distinct from the first dicing station. The control module is adapted and configured to control functions of the first dicing station modules and is further capable of being positioned at a remote location from the first dicing station.

Abstract: A method of making read sensor with self-aligned low resistance leads is provided. In the method a masking step has been eliminated by employing first, second and third protective capping layers in the construction of the read sensor and first and second lead layers. The first capping layer serves as a protective layer for the read sensor sites, the second capping layer protects low resistance lead layer portions during removal of the first capping layer from high resistance lead layer sites and then serves as a sacrificial layer during removal of spin valve material from the low resistance lead layer sites. The third capping layer protects the first and second lead layers during milling of low resistance lead layer material in field regions about the read sensor and first and second lead layers. The method aligns front edges of the low resistance lead layer portions with a rear edge of the read sensor so as to lower the overall resistance of the lead layers.

Abstract: A method of making provides a smooth surface of a pinned or free layer interfacing a barrier layer in a tunnel junction sensor wherein the smooth surface is an oxidized monolayer of the pinned or free layer. After sputter depositing the pinned or free layer the layer is subjected to an oxygen (O2) atmosphere which is extremely low for a very short duration. In a preferred embodiment of the invention a partial thickness of the barrier layer is provided with a smooth surface by the same process after which a remainder thickness of the barrier layer is deposited and the barrier layer is exposed to oxygen (O2) to form an oxide of the deposited metal.

Abstract: A dual GMR or dual spin valve sensor has a self-pinned layer which has its magnetic moment pinned perpendicular to an air bearing surface by sense current fields from conductive layers in the dual spin valve sensor when a sense current is conducted therethrough. This scheme eliminates one of the antiferromagnetic pinning layers which is typically employed in a dual GMR or dual spin valve sensor. The self-pinned layer is thin so that its demagnetization field will not be greater than the sense current fields acting thereon. Because of the thinning of the self-pinned layer the spin valve effect of the spin valve sensor is degraded by scattering of conduction electrons at the boundary of the self-pinned layer.

Abstract: In the present method for manufacturing a magnetic write head a focused ion beam (FIB) tool is utilized to mill the side edges of a P2 pole, in order to provide a narrowed track width. Prior to milling, a thin film layer of material is deposited upon the P2 pole tip. The milling boxes of the FIB tool are properly aligned upon the layer with reference to the location of the P2 pole tip. Milling of the lateral edges of the P2 pole tip is then conducted to the appropriate depth, and the layer of material is removed. The resulting P2 pole tip has sharp lateral edges, rather than the rounded edges that are produced in prior art FIB processing methods that do not utilize the thin film layer. In a preferred implementation, the FIB tool is utilized first to deposit the thin film layer and thereafter to perform the milling operation.