An actuator assembly that includes, in one example embodiment, a substrate with a bridge coupled between a first electrode and a second electrode on the substrate. A lithographically disposed flyer is positioned in proximity to the bridge. In a more specific embodiment, the actuator assembly further includes a lithographically disposed barrel that partially surrounds the flyer. A fireset is coupled to pins that extend through the substrate to the first electrode and the second electrode. The flyer further includes a three-dimensional surface adapted to flatten during flight. The flyer may be concave, convex, or may star shaped, may have perforations therein, or may exhibit another shape or other features.