An interconnect for testing a semiconductor component includes a substrate, and
interconnect contacts on the substrate configured to electrically engage component
contacts on a semiconductor component. Each interconnect contact includes a compliant
conductive layer formed as a conductive spring element. In addition, the complaint
conductive layer includes a tip for engaging the component contact and a spring
segment portion for resiliently supporting the tip. A method for fabricating the
interconnect includes the steps of shaping the substrate, forming a conductive
layer on a shaped portion of the substrate and removing at least some of the shaped
portion. The shaped portion can comprise a raised step or dome, or a shaped recess
in the substrate. The conductive layer can comprise a metal, a conductive polymer
or a polymer tape can include a penetrating structure or penetrating particles.
The interconnect can be used to construct wafer level test systems, and die level
test systems as well, for semiconductor components such as wafers, dice and packages.