Method for head stack assembly rework

A method to manufacture a head stack assembly, the method comprising:

• providing an actuator including an arm and a flexible printed circuit (FPC) including a plurality of FPC bond pads;
• providing a first head gimbal assembly (HGA) that includes a first suspension, a first read head, and a first flexure tail including a first bonding region, the first bonding region including a first plurality of flexure tail conductive bond pads;
• attaching the first suspension to the arm;
• bonding each of the first plurality of flexure tail conductive bond pads to a corresponding one of the plurality of FPC bond pads;
• testing the HSA;
• cutting the first flexure tail to separate the first bonding region from a remainder of the first flexure tail, including leaving the first plurality of flexure tail conductive bond pads bonded to the corresponding plurality of FPC bond pads;
• detaching the first suspension from the arm;
• installing a replacement HGA on the HSA, the replacement HGA including a replacement suspension and a replacement flexure tail that terminates in a second bonding region, the second bonding region including a second plurality of flexure tail conductive bond pads, wherein installing the replacement HGA includes:
• attaching the replacement suspension to the arm,
• overlaying the second bonding region on top of the first bonding region, and
• bonding each of the second plurality of flexure tail conductive bond pads to a corresponding one of the first plurality of flexure tail conductive bond pads.