Abstract: An enhanced microfabricated spring contact structure and associated method comprises improvements to spring structures above the substrate surface, and/or improvements to structures on or within the substrate. Improved spring structures and processes comprise embodiments having selectively formed and etched, coated and/or plated regions, which are preferably further processed through planarization and/or annealment. Improved substrate structures and processes typically comprise the establishment of a decoupling structure on at least one surface of the substrate, and electromechanical fulcrum connections between elastic core members, e.g. stress metal springs, through defined openings in the decoupling structure toward electrically conductive pathways in the support substrate.

Abstract: An improved interconnection system is described, such as for electrical contactors and connectors, electronic device or module package assemblies, socket assemblies, and/or probe card assembly systems. An exemplary connector comprises a first connector structure comprising a contactor substrate having a contact surface and a bonding surface, and one or more electrically conductive micro-fabricated spring contacts extending from the probe surface, a second connector structure comprising at least one substrate and having a set of at least one electrically conductive contact pad located on a connector surface and corresponding to the set of spring contacts, and means for movably positioning and aligning the first connector structure and the second connector structure between at least a first position and a second position, such that in at least one position, at least one electrically conductive micro-fabricated spring contact is electrically connected to at least one electrically conductive contact pad.