This thesis seeks to accomplish two goals. The first one is to investigate the sensitivity of MEMS to ESD stress events thereby answering the question how big a threat ESD is to the reliability of MEMS. ESD is one of the newer and less understood problems in MEMS technology, with little published literature at the start of this thesis work, as compared to better-studied issues like creep, fatigue, charging, stiction etc. This has motivated the largely experimental and exploratory work performed in the framework of this PhD. The work involved setting up test procedures and failure criteria for ESD testing in MEMS, measuring the sensitivity levels and understanding unique failure mechanisms in MEMS during ESD stress. The investigations are performed on two main electrostatically actuated MEMS test vehicles the torsional micromirror and the capacitive RF MEMS switch, and a few other related test structures.The second objective is to propose solutions for better ESD reliability of MEMS. This has been achieved either by improving the intrinsic ESD robustness through better ESD-aware MEMS design or by implementing on-chip ESD protection strategies. Both CMOS and MEMS-based ESD protection solutions are explored in the context of both CMOS-integrated and stand-alone MEMS applications.A MEMS device can typically be subjected to ESD during many stages of its production like processing, assembly, packaging, shipping and handling, and even during normal operation. Unlike semiconductor ICs, MEMS have movable components separated by air-gaps. As a consequence, two effects can occur during an ESD event. The high voltage build-up across the air-gap during ESD might make the component move causing the air gap to reduce and eventually close. When the gap closes during the ESD event, breakdown and resulting thermal damage between the electrodes can occur, causing catastrophic failure of the MEMS. When the electrical contact remains open during the ESD event, air gap breakdown or field emission can occur causing charging of the device or even permanent damage. Which of these effects occur, depends a lot on the robustness/stiffness of the MEMS. The reliability threat of ESD is complicated by the fact that it is a randomly occurring event.Therefore to study the reliability threat under ESD stress in MEMS, standard test models which simulate real-life ESD events such as the Human Body Model (HBM) were performed at the wafer level on poly-SiGe micromirrors and Al-alloy capacitive RF MEMS switches to measure their ESD sensitivity. The voltage during the ESD event was used to monitor failure, because of the high impedance of the capacitive MEMS devices. Based on these electrical measurements which detect a change in the device resistance during failure, the micromirrors and the switches were classified as extremely ESD-sensitive Class 0 devices with a failure level < 250V. All these test devices suffered catastrophic damage upon failure.However, since MEMS are designed for different non-electrical functionalities, such as optical, mechanical, motion-based, chemical, thermal etc, the correct point of failure can be determined only by comparing their functionality measurements before and after ESD stress. It was noticed through measurements that RF MEMS switches often suffered functional failure at ESD stress levels lower than the catastrophic failure level detected electrically. It is therefore mandatory that functionality tests on MEMS be performed during and after ESD to conclusively detect failure. Customized test setups were built for this purpose by integrating a portable probe-mountable HBM ESD tester with a Laser Doppler vibrometer for out-of-plane motion measurements. Simultaneous measurements of out-of-plane displacement, current and voltage in the MEMS DUT were performed in-situ during ESD stress using this setup which enabled improved failure detection and deeper understanding of the failure mechanisms in MEMS during ESD. The test setup was also used together with a pressure controlled vacuum chamber to study the effect of pressure on the ESD sensitivity, which is of importance when testing for example resonators which have to function in vacuum. The ESD reliability of capacitive MEMS switches was found to be worse in vacuum than at atmospheric pressure. Having explored the ESD sensitivity and failure mechanisms in MEMS in the first part of the PhD as described above, the focus of the second part was on improving ESD robustness and implementing ESD protection for these devices. It is shown that the intrinsic ESD robustness of MEMS can be improved by varying design parameters to increase their mechanical stiffness since a direct correlation was found between the mechanical robustness of the MEMS, the pull-in voltage and the ESD failure level. The new structures showed a 200% increase in ESD robustness for micromirrors and a much larger improvement for the RF MEMS switches with intrinsic HBM robustness of up to 650V. However, this comes at the expense of an increased pull-in voltage which is undesired in most applications. Commonly implemented customer requirements in industry require at least 2kV HBM robustness for the shipped product in the case of consumer applications. For MEMS integrated in a CMOS chip or package to survive this high level of ESD stress, design improvements alone as described above are insufficient. ESD protection is therefore essential if the MEMS are to enter the market in a commercial application. Designing ESD protection or adapting from conventional CMOS ESD protection structures is challenging, because MEMS operate at high voltages and in both voltage polarities, have unique packaging and processing requirements and impose severe area and cost constraints on the ESD protection designer.To demonstrate the concept, ESD protection was implemented on a MEMS-on-CMOS process by adapting the silicon controlled rectifier (SCR), commonly used for ESD protection in CMOS devices, to a high trigger voltage and connected in parallel with a MEMS switch. The fabricated device improved the MEMS ESD robustness from 140V (Class 0) to 5kV. Other advanced bi-directional ESD protection devices with high turn-on voltages may be used in a similar manner in the future taking advantage of slower turn-on time requirements for MEMS and lower area constraints. In a pioneering concept, small torsional devices with fast response time to ESD stress and pre-defined trigger voltages were designed and developed as on-chip MEMS-based one-time ESD protection fuses. The purpose of these devices is to provide a MEMS process-compatible basic level ESD protection for stand-alone MEMS devices during handling between manufacturing and assembly into an electronic circuit. However, MEMS-based ESD protection to be used in standalone MEMS applications made entirely on a MEMS processing platform needs further development in order to compete with the ESD protection levels offered by CMOS devices.In conclusion, the ESD reliability threat in MEMS devices is real but can surely be overcome by a combination of smart design and processing, good choice of materials and a better understanding of failure mechanisms. The magnitude of the ESD challenge is more significant and exciting in the context of newer and smaller MEMS applications with increasing functionalities in the future. nrpages: 274 status: published