Method of manufacturing a flexible circuit compression connector

A method for forming a flexible circuit compression connector system including a plurality of contacts at preselected positions, the contacts including at least a base and a head of preselected configuration, comprising the steps of:

• providing a flexible insulating substrate;
• applying conductive material to the substrate at a plurality of preselected positions;
• extending at least one conductive line between at least two of the preselected positions;
• providing a transfer film of deformable material containing an array of apertures, each aperture including a contact having at least a base and a head of preselected configuration, the apertures being smaller than the contacts, the array positioned so that at least the portion of each contact opposite the head is alignable with the preselected positions of conductive material on the flexible insulating substrate;
• placing the transfer film against the flexible substrate so that portions of the contacts opposite the heads abut the preselected positions of conductive material on the flexible substrate, while the heads project away from the flexible substrate;
• fusing the conductive material to the portion of the contacts opposite the heads;
• and
• following the fusing, separating the transfer film from the flexible substrate and the contacts, so that the heads of the contacts project away from the substrate.