You will need:
- Conductive fabric. I used Cobaltex from Less EMF http://www.lessemf.com/fabric.html
- Wonder Under or some other iron-on adhesive sheeting (you can get it at fabric stores)
- Laser cutter
- Clothing iron
- Soldering iron
- Stuff you want to solder
- rhinestone glue (like Gemtac) for gluing your components to the fabric.
Step 1: Ironing on the wonder under
Leave the paper on, that is the side that you will be lasercutting.
Step 2: Laser cut the fabric
The laser cutter settings that you use should cut through the paper and fabric without burning away too much excess fabric. For our lasercutter (a really old Universal) that means the following settings:
- Vector cut
- 1000 PPI
- 45% power
- 40% speed
Step 3: Ironing on the traces
Mark where you want your traces beforehand (with tape or pencil) so that you can be sure you don't have any overlap. If you need to cross traces, iron on one trace first, and sandwich with a small piece of heavy non-conductive fabric so that the fabric doesn't touch.
Peel the paper backing off the traces and iron them on. Keep at least 1.5 cm of spacing between ground and signal traces.