Patent ID: 7906420

Claim:
A method for forming alloy deposits at selected areas on a receiving substrate, the method comprising the steps of: providing an alloy carrier comprising at least a first decal including a first plurality of openings formed therein and a second decal including a second plurality of openings formed therein, the first and second decals being arranged in abutting contact with one another such that each of the first plurality of openings is in alignment with a corresponding one of the second plurality of openings; filling the first and second plurality of openings with molten alloy; cooling the molten alloy in the first and second plurality of openings to thereby form at least first and second plugs, the first plug having a first surface and a second surface, the second surface being substantially parallel to the first surface, the second plug having a third surface and a fourth surface, the fourth surface being substantially parallel to the third surface; removing at least one of the first and second decals to at least partially expose at least the first and second plugs; aligning the alloy carrier with the receiving substrate so that the at least the first and second plugs substantially correspond to the selected areas on the receiving substrate; and transferring the first plug to a first of the selected areas and the second plug to a second of the selected areas, wherein contact is made between the first surface and the first selected area and between the third surface and the second selected area, wherein the transferring comprises at least one of applying a compression force, applying heat, and applying mechanical vibration to the second and fourth surfaces of the first and second plugs, respectively, such that the second and fourth surfaces are formed substantially within a same plane; wherein following the transferring step, the second and fourth surfaces of the first and second plugs, respectively, are substantially flat.