Step 3: Making Curved Circuit Boards
The bendable circuit board material can be etched by any conventional circuit board method that you prefer. The method I used for creating a resist is very simple and quick. I took inexpensive clear shelf liner which is sticky on one side and laminated the copper clad board between two layers of the vinyl shelf liner.
I then took a double bladed knife that I made (see pic5) by bolting two exact o blades to the sides of a fiberglass circuit board with the copper etched off. Pic6 shows how I cut out wherever I wanted to etch away the copper. You can cut curved lines or use a ruler to guide the double knife and cut straight lines.
pic7 shows the main body of the lamp laminated with shelf liner before cutting, etching and bending. It is 12" long.
You can of course etch very precise and complex circuit boards. I have chosen to used the curved surfaces to mount LEDs and inputs to create a simple circuit as the main body and structure. The detailed and more intricate part of the circuit is is a fast circuit module made on fiberglass perfboard. See next step.