Systems and methods for shaping flexible circuits to improve routing and attachment

A method of shaping a flexible circuit (FC) including a set of conductive traces disposed within a set of insulation layers, the method comprising:

• providing a non-conductive tool defining complimentary first and second tool portions and a shape therebetween, the tool being configured to receive a portion of the FC therebetween the first and second tool portions;
• providing a set of conductive heating elements arranged substantially in parallel with each other and disposed within the first and second tool portions;
• providing a power source configured to provide power to the conductive heating elements causing the conductive heating elements to generate heat energy;
• positioning the FC portion within the tool;
• and
• providing power to the conductive heating elements to shape the FC portion without removing any of the FC portion.