Back to your original question - how about a mechanical system that could apply copper tape to a board, with little spots of solder paste at X/Y junctions? When all done run it thru a re-flow oven to join the junctions.
Looks like width would be an issue - I seee plenty of places with 10 mil thick, but not 10 mil wide.
Perhaps some kind of sintered metal that could then be baked/cured, similar to conductive ink, but in a more solid form.Or! cover a board with a meltable powder, use laser to melt the traces into place, and then gather up the excess for the next application.
Do you have a link to this Shapelock stuff?
Sintering, yeah, just showing my lack of knowledge in that area.How about low vacuum pressure vaporization? Use laser to pretreat the areas to be coated, then put the board in a little oven for the treated areas to attract the vaporized metal (like Aluminum)? Might take a few passes for the metal to build up enough thickness to be durable for reflow soldering to attach parts.
Maybe use the salt, hydrogen peroxide, and (vinegar? alchohol? this mix was just posted in the last couple of days) as etchant.
Pretreat, I don't know. Not sure what you could do to a piece of fiberglass to make something else want to stick to it.Static electricity, conductive paint, seems like everything turns into a multi-pass process.Maybe just burning off the clearences around traces with a laser is the way to go.