Hello. The goal of this project is to attempt a DIY IEM orthodynamic driver.

Current approach will probably attempt to miniaturize HE-6 design into a 16 mm diameter form factor - 10x shrinking.
The required metallized foil can be had here: http://shackman-esl-diy-catalogue.reromanus.net/contents/en-uk/d34_Shackman_esl_diy_parts.html
Here are the magnets I'll have to use: http://www.amazon.com/MyMagnetMan%C2%AE-Smallest-Neodymium-Miniature-Electronic/dp/B00J53I988 - stack 8 of them lengthwise, separate by 1 mm.

Mounting will be made out of acrylic on our fresh new shiny laser cutter - PCB is too hard to cut this tiny.

The one part I cannot yet figure out is how to make traces on this film - etching specifically, hard mask can be made from acrylic using said laser cutter.
I don't know which etchant would be appropriate - mylar is not really acid resistant - nital for instance will probably damage or dissolve it.

EDIT: I'm also considering an attempt to apply traces using a process similar to laser trimming resistors.