Using a Silhouette Cameo Plotter to cut a flexible circuitboard from various materials. The circuit base material is Kapton, a material that can withstand the high heat of soldering. The conductive circuit traces are cut from a sheet of copper tape and transferred manually onto the Kapton base. Finally a soldermask is cut from very thin Kapton tape and stuck on top of the circuit to insulate everything that does not need to be exposed for soldering to.

Materials:

Kapton sheet material (SYNFLEX PI Film-SV2, 0.175mm thick) >> http://www.synflex.com
Copper adhesive sheets >> http://www.techsoft.co.uk/products/knife-cutting/materials/cutronic-foil-pcbs.asp
Kapton tape >> http://www.segor.de/#Q%3DKaptonband50mm%2833m%29%26M%3D1

Tools:

Silhouette Cameo plotter >> http://www.modulor.de/en/Tools-Safety-Equipment/Stationary-Machines/Cutting-plotter/Cutting-plotter-SILHOUETTE-CAMEO.html

Links:

Photos >> https://www.flickr.com/photos/plusea/sets/72157648348822379/
Laser and Vinylcut Flex PCB >> http://www.kobakant.at/DIY/?p=1132
Etched Flex PCB >> http://www.kobakant.at/DIY/?p=240

Step-by-Step

1) Prepare file on computer

The flex circuit is made up of 4 main layers: (1)Base material, (2)conductive traces, (3)jumpers, (4)soldermask.

I followed this nice tutorial on how to prepare and export your file in Adobe Illustrator in order to import it and use the Silhouette Studio:
Illustrator Designs into Silhouette Studio >> http://hodgepodgepadge.wordpress.com/2012/10/07/illustrator-designs-into-silhouette-studio/
1) “Make sure all of your shapes are with NO FILL, NO STROKE – just paths!”
2) Save as: “AutoCAD Interchange File (dxf)”
3) Open in Silhouette Studio and re-size to dimensions you had in the original Illustrator file

2) Cut Base

3) Cut Copper

4) Transfer Copper and Insert Jumpers

5) Cut and Apply Soldermask

6) Finishing

Cut/punch holes for sewing with a hole punch.