Using a 1/4 inch end mill a grid pattern of one inch squares or lands
separated by concave troughs or grooves 0.025 inches deep is milled on to
the surface of a one quarter inch thick magnesium plate. A conductive
barrier such as a titanium foil is then laid over the magnesium plate,
and is then pressed into the pattern with a one inch thick 80 durometer
rubber sheet. Pressure of 250 pounds per square inch is then applied to
the rubber to create indentations in the foil creating the same pattern
as the one on the magnesium plate. The foil is then removed. An
electrically conductive adhesive is then screen printed on the magnesium
lands only, avoiding the grooves. The titanium foil is oriented to the
pattern on the magnesium plate and mated to the magnesium plate by
applying 200 pounds per square inch of pressure.