This specification describes techniques for manufacturing an electronic
system module. The module includes flexible multi-layer
interconnection circuits with trace widths of 5 microns or less. A glass panel manufacturing facility, similar to those employed for making
liquid crystal display, LCD, panels is used to fabricate the
interconnection circuits. A
polymer base layer is formed on a glass carrier with an intermediate release layer. Alternate
layers of
metal and
dielectric are formed on the base layer, and patterned to create an array of multi-layer
interconnection circuits on the glass panel. A thick layer of
polymer is deposited on the interconnection circuit, and openings formed at input / output (I / O) pad locations.
Solder paste is deposited in the openings to form wells filled with solder. After dicing the glass carrier to form separated interconnection circuits, IC chips are stud bumped and assembled using
flip chip bonding, wherein the stud bumps on the components are inserted into corresponding wells on the interconnection circuits. The IC chips are tested and reworked to form tested circuit assemblies. Methods for connecting to testers and to other modules and
electronic systems are described. Module packaging
layers are provided for hermetic sealing and for
electromagnetic shielding. A
blade server embodiment is also described.