I have a question regarding manufacturing. Our design team is working on a product that needs to connect a Flex (2 terminals) to a cable. The flex is like 3 or 4 mm wide x 15 cms +/- long (like a strip of very thin tape). We have to connect in one of the ends to 2 jumpers cables (gage I think 30). First we tried solder lap and the flex burned, so we tried through holes but the cables are too big and we are having a tough time connecting this SOB because the flex is flexible (LOL) and it moves each time we need to connect and If you are a manufacturing engineer you know that when we kick this baby up to a 1000 a day = major scrap $$$. So the other option we have is to use a connector BUT THIS IS VERY EXPENSIVE so we need a cost effective solution to this.
ANY IDEAS??