I don't know how much money this will save you...however, for what it is
worth......

Go to a flex PCB manufacturer, have him get some copper foil...no laminate.
(flex guys are set up to handle floppy material like foil)
Put photoresist on one side...plate 0.005 tin lead on the other.
Strip photoresist.
FUSE Tin/Lead, otherwise you have only discrete chrystals of Tin/Lead, not
true alloy.
Etch Copper away....

Hope this helps.

Rudy Sedlak
RD Chemical Company

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