Photolithography patterned spring contacts are disclosed. The spring
contacts may be fabricated using thin film processing techniques. A
substrate, such as a silicon wafer or a carrier substrate is provided. At
least one layer of a metal or alloy film may be deposited on the
substrate or on at least one intervening release layer and patterned to
form metal traces. A stressable material, exhibiting an at least
partially tensile stress state, may be deposited on the metal traces in a
localized region. A portion of the substrate or a portion of the
intervening release layer underneath the metal traces may be removed by
etching, causing the metal traces to curl upward resulting in the spring
contacts. The spring contacts may be used as compliant electrical
contacts for electrical devices, such as integrated circuits or carrier
substrates. The compliant electrical contacts may also be used for probe
cards to test other electrical devices.