Patent ID: 6906540

Claim:
A method of fabricating a plurality of micro probes comprising the steps of: providing one or more masks, each of said one or more masks including a plurality of probe shapes, each of said plurality of probe shapes including a probe base, a probe shaft connected to said probe base, a probe end connected to said probe shaft, and one or more raised surfaces on at least one of said probe base, said probe end, and said probe shaft; applying a photoresist to first and second opposing sides of a metal foil; overlaying one each of said masks on opposing first and second sides of said metal foil; exposing said photoresist to light passed through each of said masks; developing said photoresist; removing a portion of said photoresist to expose a portion of said metal foil; and applying an etcher to the surface of said metal foil to remove said exposed portion to produce a plurality of probes, each of said plurality of probes including a probe base, a probe shaft connected to said probe base, a probe end connected to said probe shaft, and one or more raised surfaces on at least one of said probe base, said probe end, and said probe shaft.