Processes for packaging integrated circuits in microarray packages are
described. In a method aspect of the invention, a first side of a metal
sheet is etched to define a lead frame panel having a plurality of device
areas. Each device area includes an array of contact posts suitable for
forming contact pads and a plurality of lead traces. Each lead trace is
coupled to an associated contact pad. The etching is arranged so that it
does not etch all of the way through the metal sheet. Rather, the etching
thins portions of the lead frame panel apart from the contact posts and
lead traces to form a thin connecting sheet that holds the contact posts
and lead traces in place. With this arrangement, the contact posts and
lead traces defined in the resulting lead frame structure are held in
place by the thin connecting sheet and are raised relative to the
connecting sheet. The resulting etched leadframe panel is particularly
well suited for use in microarray packages. In various embodiments, other
lead frame structures may be incorporated into the device areas as
desired.