We are working on developing direct metalization process for flex-rigid pwbs 
using palladium based process.   Currently we are very early in the 
development stage and are experiencing inconsistent results.  Some of the 
test results were very good others failed.  The failures exhibited rough 
hole walls and voids.  The roughness appears to be caused by something 
flaking off of the hole wall and plating.  The appearance is similar to 
blistered or peeling electroless.  Does anyone run flex-rigid through a 
direct metalization process?  If so, has anyone
experienced similar problems and what is the cure?