Patent ID: 7071012

Claim:
A process for reconstructing a semiconductor wafer, comprising: forming at least a first alignment droplet and at least a second alignment droplet from a flowable alignment material at laterally spaced locations on a substrate; placing a first semiconductor die having at least one alignment cavity on a surface thereof, such that the at least one alignment cavity of the first semiconductor die makes contact with the at least a first alignment droplet and is positioned by surface tension thereof; placing a second semiconductor die having at least one alignment cavity on a surface thereof, such that the at least one alignment cavity of the second semiconductor die makes contact with the at least a second alignment droplet and is positioned by surface tension thereof; inducing the at least a first alignment droplet and the at least a second alignment droplet to at least partially solidify to maintain positions of the first semiconductor die and the second semiconductor die; and subsequently introducing an underfill material between the surfaces of the first and second semiconductor dice and the substrate to substantially fill a volume between each of the first and second semiconductor dice and the substrate, to extend laterally between the first and second semiconductor dice and to surround the at least a first alignment droplet and the at least a second alignment droplet to form a reconstructed semiconductor wafer.