Designed and validated a mechanical docking interface to achieve repeatable, controlled engagement between a probe card and top-load prober under load. Developed a hardware test platform to replicate real system boundary conditions, using a rigid 80/20 structure and a pneumatically actuated cylinder to simulate chuck forces up to 100 kg.

Instrumented the system with an in-line load cell for force verification and high-resolution Keyence displacement sensors to measure structural deflection in real time. Collected force–displacement data across the operating range to characterize system stiffness and identify non-linear compliance in the probe card stackup.

Used this data to iteratively tune preload and interface design, balancing sufficient contact force with compliance to avoid damage and ensure reliable electrical engagement. This work established a quantitative understanding of load paths and stiffness, enabling predictable, repeatable performance of the docking system.