Patent ID: 8318595

Claim:
A method of self-assembling microscale structures, said method comprising: providing a microscale part comprising a mechanical binding site and an electrical binding site; providing a template comprising: a bump structure comprising a solder alloy; a fluid having a melting point lower than that of said solder alloy; and a carrier fluid medium transporter; liquefying said carrier fluid medium transporter and lower melting point fluid to allow stochastic capture and self-assembly of said microscale parts from said carrier fluid onto said template and to allow said bump structure to align with said electrical binding site using capillary forces from said carrier fluid, and wherein said solder alloy only liquefies at a temperature above that at which said self-assembly and alignment is performed; liquefying said solder alloy to form electrical connections with said electrical binding sites; and solidifying said solder alloy after self-assembly and alignment of said bump structure with said electrical binding sites causing said bump structure solder alloy to bind with said mechanical binding site.