Patent ID: 8518204

Claim:
A method of fabricating a micro device comprising: bonding a first substrate stack to a second substrate stack with an intermediate electrically conductive bonding layer having a liquidus temperature of 350° C. or lower; patterning an active device layer of the first substrate stack to form a plurality of micro devices; heating a region of the intermediate electrically conductive bonding layer to the liquidus temperature or higher; picking up one of the plurality of the micro devices and a portion of the intermediate electrically conductive bonding layer with a transfer head; placing the micro device and the portion of the intermediate electrically conductive bonding layer on an electrically conductive receiving bonding layer on a receiving substrate; and bonding the intermediate electrically conductive bonding layer to the electrically conductive receiving bonding layer to form a permanent alloy bonding layer having a liquidus temperature above 150° C.