A process for selectively depositing a filled underfill material onto a
die surface without covering solder bumps present on the die. The process
entails microjetting a polymer matrix material, a filler material, and
optionally a fluxing material onto the die surface. Together, the polymer
matrix and filler materials define the filled underfill material in which
the filler material is dispersed to reduce the coefficient of thermal
expansion of the underfill material. The resulting underfill material
surrounds but does not cover the solder bumps. The die is then placed on
a substrate on which a second underfill material is present, forming a
composite underfill layer that completely fills the space between the die
and substrate and forms a fillet on a peripheral wall of the die.