Next Generation IC Probe Card Manufacturing via Precision Laser Processing (ProLase)

The aim of this project is to provide more efficient and accurate solutions for the semiconductor test industry by designing, developing, and demonstrating next-generation high-density vertical MEMS probe card (HD-VPC), that meet the accuracy and precision requirements of high-performance semiconductor products. By developing and applying this new probe card, the project seeks to further advance the global semiconductor industry.

The HD-VPC probe cards will consist of four components: probes, multi-layer IC/PCB substrate or circuit extender, space transformer and a probe card guide plate. The UK-based work will focus on the fabrication of the probe card guide plate, made up of ceramic material, through precision laser cutting and drilling processes. Laser cutting will be used to produce the guide plate substrate to the required size, followed by the drilling of high-precision holes over the guide plate for the probes.

The probes, made from multi-alloy materials, will offer improved wear resistance and electrical conductivity. The assembled probe cards will undergo high-frequency electrical characteristics testing, mechanical strength testing, and long-term reliability assessments to ensure their performance and reliability.

This project represents a significant leap forward in probe card technology, addressing current limitations and setting new standards for size, precision, and scalability in the semiconductor industry. By improving the overall performance and reliability of probe cards, it will lead to more efficient and accurate semiconductor testing. Through fostering innovation across design, manufacturing, and assembly of HD-VPC, this project will enable the production of advanced semiconductor devices, driving economic growth and establishing the UK as a leader in high-value semiconductor component manufacturing.

Additionally, it will make the UK a key supply chain player in the global vertical probe card market, estimated to be $2.2 billion in 2027 with expected growth at a CAGR of 8.8%.