A semiconductor package includes a substrate formed of a board material, a
semiconductor die bonded to the substrate, and an encapsulant on the die.
The package also includes an array of external contacts formed as multi
layered metal bumps that include a base layer, a bump layer, and a
non-oxidizing outer layer. The external contacts are smaller and more
uniform than conventional solder balls, and can be fabricated using low
temperature deposition processes, such that package warpage is decreased.
Further, the external contacts can be shaped by etching to have generally
planar tip portions that facilitate bonding to electrodes of a supporting
substrate. Die contacts on the substrate can also be formed as multi
layered metal bumps having generally planar tip portions, such that the
die can be flip chip mounted to the substrate. A method for fabricating
the package includes the step of depositing the different layers for the
metal bumps using electroless and electrolytic deposition, and then
etching the different layers to shape the metal bumps.