Abstract: A phased array antenna system including a mandrel having compliant portions and an internally formed cooling passageway. The compliant portions are formed by removing portions of material along one end of the mandrel to form a plurality of pairs of generally U-shaped, leaf spring-like connecting areas. The connecting areas allow a degree of movement of a lower portion of the mandrel relative to the remainder of the mandrel, when the mandrel is fixedly secured to a printed wiring board (PWB). This enables flexible electrical interconnects, positioned over the compliant portions, to make electrical contact with circuit traces on the PWB, even if the PWB has a curved or undulating surface.

Abstract: An apparatus and method for forming and bonding of flexible circuits to metal structures includes a clamping frame having a removable frame portion. At least one flexible roller fixture provides opposed flexible rollers. A clearance aperture in the roller fixture is sized to slidably receive the clamping frame. As the clamping frame is inserted through the clearance aperture of the roller fixture the opposed flexible rollers apply a continuous pressure to deflect the flexible circuit. A curing clamp is then connected to the clamping frame having at least one engagement face defining a flexible circuit finished shape. The flexible circuit is then heat cured to adhesively bond to the metal structure.