The pictures below are of a prototype area array solder connection using 7 single sided flex circuits laminated together.  One end is used to terminate double sided flex to one of the 7 single sided flexes, and the other presents an array of the 7 single layers to be soldered to a matching array.  Below are pictures of the solder fixture and parts

Low Mass Cable Manufacturing
	This is a picture of the exposure table used to make the electrode strips of the STAR TPC. The strips were double sided Cu-Kapton flex circuit material patterned on both sides. The artwork seen on the table is 200mm wide X 14.5m long and aligned optically over its full length to better than 0.025mm. While not evident in this picture, there is another UV lamp underneath the table allowing for simultaneous exposure of the underside. This basic design was used to construct a table for ATLAS pixel flex cables. The new table is only 6m long, but has a 300mm wide aperture.
	Using essentially the same design a 5m table was constructed in Bldg 25 in the PCB fab shop. The table is wider, allowing a full 300mm between integrated vacuum channels. The vacuum channels help to hold the flex material between the two layers of art during the exposure. Standard Stoesser pins register the art to the table physically.
	The prototype artwork has all cable types integrated into one piece of art. For these cables, the top and bottom are mirror images of each other so that the emulsion side of the artwork is against the photoresist during exposure. This artwork, 2 pieces each 5.5m long cost $6.6k.
	Here is the completed table. The orange plastic cover both protects the artwork from dust as well as cuts out extraneous UV from the fluorescent overhead lighting. The Xenon UV lamps from the STAR table were salvaged and used here. Even the motion control system, controllers and limit switches were mostly recuperated from the STAR table. The table as completed represents ~2man months labor, ~$3k in unistrut, and $1k craft labor for electrical drop.
	This is a production run, shown with the UV lamp on. The exposure is controlled by the velocity of the trolley. A fairly simple pulley system and variable speed motor move both lamps along the length of the artwork to fully expose the photo-resist. The photoresist (RISTON) is laminated to both sides of the flex in the lamination room next door. After exposure the resist is developed, and touched up. The time from expose/develop to when it is etched must be kept to a minimum to prevent embrittlement of the photoresist layer.
	Here is a frame just exiting the etcher. We have successfully etched both Al and Cu, for STAR, and have replicated these results using this new artwork. The End
More pictures of the Exposure table on Tom Weber's Page