Method of manufacturing flexible electronic circuits having conformal material coatings

A method of manufacturing a flexible electronic circuit, comprising:

• pressing a screen onto a flexible polymer substrate having a plurality of metal traces, wherein the screen has a porous portion and a blocked portion, and the blocked portion defines a mold;
• applying a conformal material coating to the top of the screen enabling the conformal material to flow through the porous portion of the screen filing around the mold;
• driving the conformal material coating through the screen and removing an excess of the conformal material from the screen by running a blade over the screen;
• removing the screen to reveal a cavity defined by the conformal material coating;
• dispensing an anisotropic conductive paste into the cavity;
• and
• inserting a chip into the cavity and bonding the chip to the metal traces.

A flexible electronic circuit, comprising:

• a flexible substrate having a plurality of metal traces;
• a conformal material coating, which defines at least one cavity;
• a first chip bonded into the at least one cavity;
• anisotropic conductive paste that surrounds the first chip within the at least one cavity;
• wherein at least one surface of the first chip is exposed to the surrounding environment and the conformal material coating has a thickness that is less than or equal to a thickness of the first chip.