Simple Single-Layer Flexible PCB – KiCad Manufacturing Preparation

I have an existing KiCad PCB layout for a single-layer flexible PCB. The basic copper routing/layout is already complete.

I need an experienced PCB designer with flex-PCB fabrication experience to finish the manufacturing-specific design and prepare the PCB for fabrication.

The existing copper layout should be preserved where practical, but the five dome-switch contact areas may be adjusted as necessary to correctly accommodate 5 mm metal snap domes.

PCB Material
Polyimide (PI) flexible PCB
Approximately 0.1–0.15 mm PCB thickness before stiffeners
Single copper layer
Existing PCB layout to be used as the starting point

Coverlay:
Add coverlay to the PCB everywhere except the required exposed areas.

Coverlay openings are required over:
All 5 dome-switch contact areas
All connector fingers
The coverlay must be represented using the appropriate KiCad layers so that the correct manufacturing Gerbers can be generated.
The coverlay openings must correctly expose the required copper contact areas for each dome switch.

Dome Switches:
There are 5 metal snap-dome switches.
Each dome sits directly over one pair of U-shaped copper traces.

The switches are:
5 mm round metal snap domes
Evenly spaced along approximately 44 mm
Centred within the approximately 8 mm PCB width
Installed manually by me after PCB fabrication
Not soldered components

The dome switches themselves are not part of this fabrication job. I will source and install the five 5 mm round metal snap domes myself after PCB fabrication.
The existing PCB contains five U-shaped copper contact areas for the dome switches.
These contact areas may be modified or adjusted as necessary to correctly accommodate 5 mm dome switches.
However, the overall PCB layout and functionality should be preserved.

Stiffeners - There are two stiffener areas.

1. Connector Stiffener
Location: connector tail area
Size: 5.4 mm wide × 10 mm long
Material: Polyimide (PI)
Thickness: 0.2 mm
Side: Opposite the copper routing

2. Dome-Switch Stiffener
Add a stiffener underneath the PCB section containing the five dome switches.
The stiffener should support the entire area beneath the five dome contacts shown in the existing PCB layout.
Material: Polyimide (PI)
Thickness: Appropriate thickness to be determined by the designer
Located on the underside of the PCB
Must provide suitable mechanical support for operation of the five domes
Must not interfere with the flexible portions of the cable
Please determine the appropriate stiffener geometry from the existing PCB layout.

Manufacturing Design

Please ensure the final design correctly represents:
Copper
Polyimide substrate
Coverlay
Coverlay openings
Connector fingers
Connector stiffener
Dome-switch stiffener
Five 5 mm dome-switch contact areas
Board outline
Any other manufacturing-specific requirements for the flex PCB

Please use appropriate KiCad layers and standard flex-PCB manufacturing conventions.

The completed design should be suitable for fabrication by a professional flex-PCB manufacturer.

Deliverables
Please provide:

Completed KiCad PCB design file(s) with all manufacturing-specific layers included
Complete Gerber manufacturing files generated from the final KiCad design
Drill files, if required
Any separate stiffener dimensions, drawings, artwork or files required by the PCB manufacturer to correctly specify and fabricate the two stiffener areas.
Any other files required by the PCB manufacturer

Please inspect the generated Gerbers in a Gerber viewer and confirm that the manufacturing output correctly represents the intended PCB, including:

Coverlay openings
Connector fingers
Dome-switch contact areas
Board outline
Connector stiffener

The KiCad source files and complete manufacturing Gerbers must both be supplied as final deliverables.

Starting Material

I will provide the existing KiCad PCB layout.

The existing design should be used as the starting point. The freelancer may modify the five dome-switch contact areas as necessary to correctly accommodate 5 mm round metal snap domes, but should otherwise preserve the existing PCB design and routing.

The goal is a complete, manufacturing-ready flex PCB design, with the five 5 mm dome switches able to be manually installed after fabrication.