Rigid-Flex PCBs
Rigid-flex PCBs combine flexibility with stability for high-reliability electronics.
Available structures for Rigid Flex PCBs
There are numerous, different structures available. The more common ones are defined below:
Traditional rigid flex construction (IPC-6013 type 4) Multilayer rigid and flexible circuit combination containing three or more layers with plated through holes. Capability is 22L with 10L flex layers.
Asymmetrical rigid flex construction, where the FPC is situated on the outer layer of the rigid construction. Containing three or more layers with plated through holes.
Multilayer rigid flex construction with buried / blind via (microvia) as part of the rigid construction. 2 layers of microvia are achievable. Construction may also include two rigid structures as part of a homogeneous build. Capability is 2+n+2 HDI structure.
Feature | Technical specification |
|---|---|
Number of layers | 4-26 layers |
Technology highlights | Mixed materials including RF and high speed, standard FR-4, polyimide flex. Adhesiveless or adhesive based polyimide flex constructions, with cover coat or flexible solder mask materials |
Bending performance | Based on the specific design, the bend performance can range from a basic 90 bend to fit to a full dynamic flex with 360 range of motion in the flex tail that will withstand continuous cycles throughout the product life |
Bend features | Bend radius controls the flexibility of the flex portion of the board. The thinner the material the lower the bend radius and the more flexible the flex section |
Materials | RA copper, HTE copper, FR-4, polyimide, adhesive |
Copper weights (finished) | 0.5 OZ, 1 OZ, 2OZ, 3OZ |
Minimum track and gap | 0.075 mm / 0.075 mm |
PCB thickness | 0.40 mm – 3.0 mm |
PCB thickness in flex section | 0.05mm x 0.8mm |
Maxmimum dimensions | 457mm x 610mm |
Surface finishes available | ENIG, OSP Immersion tin, Immersion silver |
Minimum mechanical drill | 0.20 mm |
Why SprintPCB can Provide the most
competitive PCBs
Under the long-term strategic cooperation agreement with laminate supplier , the price we get is 10% cheaper than most competitors
PCB Inner / outer layers fab with LDI equipment, the automatic production reduce our labor cost 5%
Lean manufacturing increases product yield
What is a Rigid-Flex PCB?
The development of Flexible Printed Circuit (FPC) and Printed Circuit Board (PCB) technology has led to the creation of Rigid-Flex PCBs. A Rigid-Flex PCB combines flexible and rigid circuit boards, integrated through processes like lamination, to form a board that possesses the characteristics of both FPCs and PCBs.
Advantages of rigid-flex boards
Versatility: Rigid-Flex PCBs offer the flexibility of FPCs and the rigidity of traditional PCBs, making them ideal for applications with specific requirements. They can have both flexible areas and rigid areas, helping to save space within products, reduce overall size, and enhance performance.
Space-Saving: The ability to combine flexible and rigid sections allows for more efficient use of space within a device.
Performance Improvement: The mixed characteristics can improve the overall performance of the product.
Challenges in Manufacturing Rigid-Flex PCBs
Flexible Section
Material Handling: Since flexible materials are soft and thin, they must be carefully handled to avoid defects. Using a carrier plate can help prevent damage during processing.
Laminating PI Coverlay: The polyimide (PI) coverlay must be laminated correctly, ensuring the pressure during quick pressing reaches 2.45 MPa and avoiding issues like bubbles.
Rigid Section
Core Windowing and PP: Deep milling is used to create windows in the rigid core, and no-flow prepreg (PP) is used to control resin flow during lamination.
Expansion and Shrinkage Control: The flexible material's expansion and shrinkage must be accounted for when making the rigid sections to ensure proper alignment and performance.
Why Use Rigid-Flex PCBs Despite Their Higher Cost?
Reliability
Installation Reliability: Rigid-Flex PCBs address the reliability issues associated with installing FPCs, such as connection stability and preventing short circuits or disconnections that can occur with connectors.
Overall Cost Efficiency
Cost Reduction: Rigid-Flex PCBs eliminate the need for connectors, reduce assembly time, and lower the defect rate. For high-volume products, this can lead to significant cost savings.
Simplified Management: Reducing the number of different board types needed simplifies inventory management and can further reduce costs.
Improved Signal Quality
Signal Integrity: Direct connections within a Rigid-Flex PCB ensure better continuity and signal integrity compared to using connectors, which can be crucial for high-frequency applications.
Design Considerations for Rigid-Flex PCBs
Bend Radius: Ensure the flexible section has an appropriate bend radius to avoid damage.
Space Optimization: Efficiently design the layout to minimize the overall area and reduce costs.
3D Space Utilization: Consider the three-dimensional space requirements for installation.
Layer Management: Optimize the number of layers in the flexible section for the best design balance.
About SprintPCB
We can provide competitive prices and guarantee the quality requirements of customers without excess quality. Our technical level can meet most of the industrial control and consumer products.
Manufacturing Equipment at SprintPCB
SprintPCB operate with most advance equipment in the industry to provide efficient production and high quality products with value added to our partners
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In the race to build tomorrow, SprintPCB engineers and PCB designers continually patent new technologies,
crossing design barriers—to help innovators bring new products to market.
"I am extremely satisfied with the quality of the PCBs you manufacture. The solder pads on each board are very smooth and the connections are very strong. I have worked with other manufacturers before, but the quality was always subpar. Since switching to SprintPCB, the quality of my projects has significantly improved. Thank you for your outstanding manufacturing process!"
- John Smith
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FAQ about Rigid-flex PCBs
A rigid-flex PCB is a type of printed circuit board that combines the benefits of rigid and flexible PCBs into one product. It consists of a rigid inner layer and a flexible outer layer, which allows for better versatility and flexibility in design and usage.
A standard PCB is typically made of a single layer of material and can only bend or flex to a limited degree. A rigid-flex PCB, on the other hand, has multiple layers and can bend and flex more easily, making it ideal for applications that require a lot of movement or compact design.
Rigid-flex PCBs offer improved durability, reduced space requirements, and better electrical performance compared to standard PCBs. They are also better suited for harsh environmental conditions, such as extreme temperatures, shock and vibration.
Rigid-flex PCBs are widely used in the aerospace, medical and telecommunications industries, among others.
The production process for a rigid-flex PCB is similar to that of a standard PCB, but with additional steps to create the flexible and rigid layers. The flexible layer is typically made from a polyimide material, while the rigid layer is made from a traditional PCB material, such as FR4. The two layers are then combined and laminated together to create the final product.
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