Gents,
Has this been done before?
PCBs can be made with great accuracy, to within 0.02mm and hole sizes down to well under 1mm.
A single sided PCB (in this case unetched) can be shaped and drilled to great tolerances, including circular. Using a fibreglass based board would ensure that it's flat and rigid.
In a one-off application this is expensive, but with a dozen or so (remember no etching required) it should become feasable in terms of cost.
Anyone had ideas in this direction?
Steve A.