Epoxy die attach is widely used in microcircuit assembly and enjoys advantages such as ease of deposition, fast curing, reworkability, and non-toxicity. These qualities also make it suitable for automated mass production. However, this method falls short when high placement accuracy is desired as the die can shift on uncured epoxy leading to die displacement from its original location. Gold to gold face-up bonding is another method utilized in microelectronics packaging given its proven bonding reliability and high placement accuracy for small devices. Nevertheless, it is difficult to achieve a reliable bond using this method for relatively larger devices. The nonplanarity of the bonding collet or the variation in the height of the gold bumps results in a tilted die attach and/or a weak bond between the die and the substrate. Moreover, CTE (Coefficient of Thermal Expansion) mismatch between the die, the gold bumps, and/or the substrate leads to bond failure due to temperature fatigue. This paper discusses a hybrid method to take advantage of the strengths of both methods mentioned above, culminating in a reliable process with high XYZ placement accuracy. To apply this method, epoxy is first dispensed on a gold-plated substrate. Using a flip chip machine, samples with plated gold bumps on their ground side are then placed on the substrate. The gold bumps are mainly used as targets and stand-offs to improve the placement accuracy and to control epoxy glue-line thickness. The force applied on the die, the time the force is applied, and the substrate temperature are controlled for optimum die attach. Moreover, along with the force applied by the vacuum tip, epoxy is partially cured on the flip chip machine heated stage before it is moved to an oven to complete the cure process. Die shear test results before and after temperature conditioning are compared with standard epoxy die attach and gold to gold face-up bonding for identical samples and the advantages are discussed.

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