In one embodiment, a solder preform includes a solder matrix having
microparticles secured with the solder matrix. The microparticles are
constructed so as to be capable of arranging during a solder bonding
process so as to provide a uniform separation between opposing soldered
surfaces. The microparticles may be shaped to inhibit stacking of the
microparticles while self arranging during the solder bonding. The solder
preform may have an amount of microparticles with respect to the solder
matrix to inhibit stacking of the microparticles during the solder
bonding process. Microparticles may be spheres, powders, polyhedrons,
crystalline particles, nanostructures, or the like, which may be capable
of conducting electric current, or may be dielectric material; for
example glass, plastic, metal, or semiconductor material. In one
implementation microparticle loaded solder preform may be fabricated by
selecting microparticles capable of self arranging within a solder alloy
so as to provide a uniform separation between opposing solder surfaces
during a solder bonding process, combining the microparticles with the
solder alloy, and forming a solder preform having a solder matrix with
the microparticles embedded therein. This may include mixing the
microparticles and solder alloy by shaking, folding, stirring, pressing,
or rolling. Some implementations, may include tailoring a coefficient of
expansion of the solder preform by selecting and combining appropriate
microparticles with the solder alloy.