Endoscopic system with electrical bridge in distal tip

A method of constructing an endoscope including an electrical bridge structure coupling an image processor to a packaged image sensor, the method comprising:

• providing an electrical bridge structure including a cross-sectional area no greater than that of the packaged image sensor, and including a plurality of electrical contacts on a distal face arranged in an array, wherein the step of providing an electrical bridge structure includes 3D printing the bridge structure with a paste comprising ceramic particles, a paste comprising conductive metal particles, and a paste comprising sacrificial support particles, the bridge structure comprising:
• (a) a pre-formed insulative body including a distal surface with a cross sectional size no greater than that of the packaged image sensor;
• (b) a plurality of pre-formed electrical contacts disposed along the distal surface of the pre-formed insulative body;
• (c) a plurality of pre-formed conductive paths through the pre-formed insulative body connecting to respective ones of the pre-formed electrical contacts;
• and (d) a plurality of pre-formed wire attachment contacts connecting to respective ones of the pre-formed conductive paths, formed within the cross-sectional area of the pre-formed insulative body, and elongated in a longitudinal direction perpendicular the distal surface, and firing the 3D printed bridge structure to cure the insulative body, conductive paths, electrical contacts, and wire attachment contacts while burning away the sacrificial support particles to form the electrical bridge;
• placing the packaged image sensor in an elongated cradle fixture;
• placing the electrical bridge structure in the elongated cradle fixture with the plurality of electrical contacts in physical contact with a respective BGA contacts of the packaged image sensor;
• and
• reflow soldering the BGA contacts of the packaged image sensor to the electrical contacts of the electrical bridge structure while they are both positioned in the elongated cradle fixture.