Patent ID: 8329493

Claim:
A method of embedding a surface mount device (SMD) package into a stretchable electronic circuit, comprising: forming an SMD mold by mounting an outer face of a first SMD package to a rigid plate, the first SMD package having conductor contact protrusions; positioning the SMD mold onto a stretchable base substrate having stretchable conductors formed onto a surface thereof, and with the conductor contact protrusions of the first SMD package contacting the stretchable conductors; filling a volume between the base substrate and the rigid plate with uncured stretchable fill material; curing the fill material to form a stretchable sensor layer; removing the SMD mold to expose an SMD cavity formed into the stretchable fill layer; and installing a second SMD package into the SMD cavity, with conductor contact protrusions of the second SMD package being in electrical communication with the stretchable conductors on the base substrate to form a stretchable electronic circuit.