Fold flex circuit for LNOP

An efficient flexible circuit physiological sensor manufacturing method, the method comprising:

• providing a sheet of flexible circuit substrate material;
• printing a plurality of nested conductors on the sheet of flexible circuit substrate material to form a plurality of individual flexible circuits,
• wherein each of the plurality of individual flexible circuits comprises a first end, a second end, and a body portion extending between the first end and the second end,
• wherein each of the plurality of individual flexible circuits are aligned on the sheet of flexible circuit substrate material such that each of the individual flexible circuits is nested into another of the individual flexible circuits, and
• wherein a center portion of the body portion of each of the plurality of individual flexible circuits shares a border with the body portion of another of the plurality of individual flexible circuits;
• and
• cutting the sheet of flexible circuit substrate material to separate each of the plurality of individual flexible circuits, wherein the first end of each of the plurality of individual flexible circuits comprises a connector portion and the second end of each of the plurality of individual flexible circuits comprises a detector portion.