Patent ID: 7297563

Claim:
A method of making a contactor card to test a semiconductor wafer, comprising: defining at least one first side location for at least one first side contact pin on a first side of a substrate, the at least one first side location corresponding in position to at least one contact on the semiconductor wafer; thinning the substrate on the first side of the substrate around each of the at least one first side location to allow a contact end to extend above the first side of the substrate; locally thinning on the first side of the substrate to form a first side void immediately around each of the at least one first side location of the at least one first side contact pin to at least a depth of the at least one first side contact pin; filling the first side void with a compliant coupling material; and thinning a second side of the substrate to release the at least one first side contact pin in the first side void from the substrate.