Patent ID: 7637007

Claim:
A method for fabricating probes for a probe card assembly, the method comprising: forming a plurality of conductive traces on a substrate; forming a plurality of posts on the plurality of conductive traces; aligning a beam panel having a plurality of beam elements formed therein to the substrate so that the plurality of beam elements are in contact with the plurality of posts and wherein: each beam element from the plurality of beam elements includes a first end portion and a second end portion, each beam element from the plurality of beam elements is in contact with a post element from the plurality of post elements at a portion of the beam element other than the first end portion or the second end portion so that both the first end portion and the second end portion overhang the post element, and each beam element from the plurality of beam elements is attached to the beam panel by the first end portion; causing the plurality of beam elements to be bonded to the plurality of posts; cutting the first end portion of the plurality of beam elements to release the plurality of beam elements from the beam panel; and removing the beam panel, leaving the plurality of beam elements attached to the plurality of post elements.