Embodiments of the present invention are directed to the formation of
microprobe tips elements having a variety of configurations. In some
embodiments tips are formed from the same building material as the probes
themselves, while in other embodiments the tips may be formed from a
different material and/or may include a coating material. In some
embodiments, the tips are formed before the main portions of the probes
and the tips are formed in proximity to or in contact with a temporary
substrate. Probe tip patterning may occur in a variety of different ways,
including, for example, via molding in patterned holes that have been
isotropically or anisotropically etched silicon, via molding in voids
formed in over exposed photoresist, via molding in voids in a sacrificial
material that have formed as a result of the sacrificial material
mushrooming over carefully sized and located regions of dielectric
material, via isotropic etching of a the tip material around carefully
sized placed etching shields, via hot pressing, and the like.