Multi-offset die head

1. An upper die portion of a die head for aligning a plurality of probes, at least one of said plurality of probes having a first lateral distance between its tip and head thereby defining a first offset and at least one of said plurality of probes having a second lateral distance between its tip and head that is different from said first lateral distance thereby defining a second offset, in a first array of first micro-holes formed in a lower die portion of the die head, comprising:

a spacer portion including first and second surfaces, said first surface for contacting the lower die portion; and

a first assembly aid film attached with said second surface and having a second array of second micro-holes for receiving said plurality of probes, said second micro-holes including at least a first micro-hole that is configured to be offset from a corresponding micro-hole of said first micro-holes by a distance equal to said first offset and at least a second micro-hole that is configured to be offset from a corresponding micro-hole of said first micro-holes by a distance equal to said second offset, wherein a pair of corresponding micro-holes releasably contains different portions of a single one of said plurality of probes.

2. An upper die portion according to claim 1 , further comprising:

a support frame positioned adjacent said first assembly aid film; and

an upper die plate joined with said support frame and having a third array of third micro-holes for receiving the probes, wherein said third array of third micro-holes are patterned to align with said second array of second micro-holes.

3. An upper die portion according to claim 2 , wherein said second and third arrays are configured to be offset from the first array.

4. An upper die portion according to claim 2 , wherein said first assembly aid film is at least semi-transparent.

5. An upper die portion according to claim 2 , wherein each of the micro-holes of said second array of second micro-holes has a diameter that is selected so that each of the micro-holes of said second array of second micro-holes is substantially sealed when the probes are inserted.

6. An upper die portion according to claim 2 , wherein said upper die plate is not fixed to said support frame.

7. An upper die portion according to claim 1 , wherein said first assembly aid film is bonded to said support frame.

8. An upper die portion according to claim 2 , wherein each of the micro-holes of said second array of second micro-holes has a diameter that is selected so that debris is substantially prevented from passing through said second micro-holes.

9. An upper die portion according to claim 1 , wherein said first assembly aid film is at least partially fabricated from a polymer film formed from a polyimide.

10. A die head including alignment mechanisms for aligning probes having different offsets in the die head, comprising:

a plurality of probes, at least one of said plurality of probes having a first lateral distance between its tip and head thereby defining a first offset and at least one of said plurality of probes having a second lateral distance between its tip and head that is different from said first lateral distance thereby defining a second offset;

a lower die portion having multiple surfaces, at least one of said multiple surfaces having a first array of first micro-holes for receiving said plurality of probes; and

an upper die portion having a spacer portion, a first assembly aid film, a support frame positioned adjacent said first assembly aid film, and an upper die plate joined with said support frame and having a third array of third micro-holes for receiving said plurality of probes, wherein said third array of third micro-holes are patterned to align with a second array of second micro-holes, said spacer portion including first and second surfaces, said first surface in contact with at least one of said multiple surfaces of said lower die portion, said first assembly aid film attached with said second surface, said first assembly aid film having a second array of second micro-holes for receiving said plurality of probes, said second micro-holes including at least a first micro-hole that is configured to be offset from a corresponding micro-hole of said first micro-holes by a distance equal to said first offset and at least a second micro-hole that is configured to be offset from a corresponding micro-hole of said first micro-holes by a distance equal to said second offset, wherein a pair of corresponding micro-holes releasably contains different portions of a single one of said plurality of probes.

11. A die head according to claim 10 , wherein said second and third arrays are offset from the first array.

12. A die head according to claim 10 , wherein said first assembly aid films is at least semi-transparent.

13. A die head according to claim 10 , wherein each of the micro-holes of said second array of second micro-holes has a diameter that is selected so that each of the micro-holes of said second array of second micro-holes is substantially sealed when the probes are inserted.

14. A die head according to claim 10 , wherein said upper die plate is not fixed to said support frame.

15. A die head according to claim 10 , wherein said first assembly aid film is bonded to said support frame.

16. A die head according to claim 10 , wherein each of the micro-holes of said second array of second micro-holes has a diameter that is selected so that debris is substantially prevented from passing through said second micro-holes.

17. A die head according to claim 10 , wherein said first assembly aid film is at least partially fabricated from a polymer film formed from a polyimide.