A probe for an array of interconnecting leads between a PCA and an IC has
one or more contacts extending laterally from or plated upon one or more
arms formed of a flexible printed circuit, and connected by traces along
the arm(s) to a header that itself affords connection to measurement
equipment. The flexible printed circuit is thin enough to loosely slide
between the top of the PCA or PCB and the bottom of the IC. The arm or
arms is/are narrow enough to slide between the adjacent leads forming the
array, while the normally flat contacts will successively interfere with,
to engage and electrically contact, consecutive layers of leads as the
probe is progressively inserted. An arm is not so stiff that it cannot
yield by a slight compressive warping as the contacts encounter leads.
Indexing may be `by feel` or by visible indicia along a top surface of
the probe or by a reticle device that moves over the top of the IC, which
then has a pattern of indicia corresponding to lead location. Forming the
shape of a Kapton substrate may also include use of a CVL operating in
the range of 250 nm to 290 nm for the creation of extended copper
contacts by the removal of underlying Kapton. Plating processes may also
be used in the fabrication of (non-extended) wrap-around contacts at the
edges of the Kapton.