Rigid-Flex PCBs

Rigid-flex PCBs combine flexibility with stability for high-reliability electronics.

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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.

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FAQ about Rigid-flex PCBs

What is a rigid-flex PCB?

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.

How does a rigid-flex PCB differ from a standard PCB?

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.

What are the benefits of using a rigid-flex PCB?

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.

What industries commonly use rigid-flex PCBs?

Rigid-flex PCBs are widely used in the aerospace, medical and telecommunications industries, among others.

What is the production process for a rigid-flex PCB like?

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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