The materials selected for the printheads used in Lexmark's Color Jetprinter™ series 7000 and 5000 inkjet printers represented radical departures from those practiced in our previous generations of thermal inkjet heads. In order to achieve cost, performance and schedule targets, significant changes were needed in the materials of construction and processes employed to assemble the printheads.This paper will focus on the evolution of the laser ablated polymer nozzle plate, a key component of the Lexmark 7000 printhead technology that has succeeded in producing print quality rivaling electrophotography. The rationale for selecting the materials set and the impact these choices had on manufacturing processes will be discussed. In addition, the testing methodology for verifying the performance of the printhead materials will be described. Materials compatibility, process capability and printhead performance data will be presented.