Patent ID: 7137547

Claim:
A method of forming a connection on a surface of an electronic carrier, the method comprising: providing a malleable wire having a first diameter via a bore of a capillary tool, the bore defining a main portion having a second diameter greater than the first diameter and defining a location portion, the location portion extending and increasing in diameter from the main portion to an end of the tool, the location portion having a third diameter, greater than the second diameter, at the end of the tool; forming a ball of material on an end of the wire, the ball of material having an initial diameter less than, or equal to, the third diameter; bonding the ball of material to a bonding surface of an electronic carrier to form a connection having a fourth diameter; extruding the ball of material through the second diameter of the main portion of the bore of the capillary tool to form a pin structures, having a diameter greater than the first diameter and less than the fourth diameter, and a weakened region between the wire and a tip of the pin structure, a majority of the ball of material being extruded through the second diameter of the main portion of the bore to form the pin structure; and disconnecting the wire from the tip of the pin structure at the weakened region.