I met Meredith Scheff at Maker Faire in NYC on September 17, 2011. She had a Maker table with sewable thread and an LED StarBoard. Her Starboard is now marketed by Sparkfun. I talked briefly with Meredith about my experiments making flexible circuit boards with bonding 1oz copper foil onto Kapton film. She informed me that Dupont sells a Pyralux, which is Kapton film with the copper pre-bonded.
Here is a cool YouTube link to Meredith: Meredith Scheff - StarBoard video.
Thanks Meredith!
I am still waiting for the samples to arrive from Dupont. In the meantime, the Starboard inspired me to experiment with some 1.6mm VAOL-S19337RGB LEDs that I has in my parts cabinet. These LEDs are extremely tiny, especially considering that they have 6 signal pins. The entire flexible Kapton circuit board is slightly smaller than a dime.
Here are images of my bare breakout board and the working wired circuit:
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