Rigid Flex Circuit Boards
Rigid flex circuit boards combine rigid printed circuit board (PCB) elements with a flexible substrate to deliver a range of benefits. They offer the design flexibility of a flex PCB with the strength of a rigid one, making them well-suited to applications in environments where vibrations might impact components. Rigid-flex circuits also reduce the number of points of failure in a product by eliminating wired connections. This increases reliability and improves shock resistance, especially in critical industries like medical and military.
Flex circuits have a much wider range of capabilities than traditional rigid flex circuit boards with wired interconnects. They can handle high-speed signals, maintain a controlled impedance, and protect against electromagnetic interference (EMI). They also work in harsher environments as they are more resistant to corrosion, chemical damage, and higher temperatures.
Unlike rigid PCBs, which are typically thicker, flex circuits have an incredibly thin base layer made of either polyester or polyimide material-films. Conductive material traces are then etched on the surface of the base layer, and the final PCB has coverlays and bondpiles to provide protection, insulation, and prevent copper from lifting during bending.
Rigid Flex Circuit Boards for Automotive Applications
The flex area in the rigid-flex circuit boards allows them to bend and twist around corners without any loss of performance. This can make a significant difference when an application has to fit into a tight space. It can also save space by removing the need for extra connectors and cables, which can be a pain to install in harsher environments. This can lead to a more cost-effective production process and shorten the time to market for your final product.
One of the most important benefits of using a rigid-flex circuit board is its weight reduction. Customers often see a 75% weight reduction when switching from a wired design to a flex circuit board. This is a result of combining the rigid PCB with the flex areas, which eliminates the need for many wired connections. It also reduces the overall size of the PCB, and can enable it to fit in places that multiple rigid and flex circuit boards, connectors, and cables wouldn’t be able to.
Another benefit is its improved drop testing performance. While drop tests aren’t a requirement in every industry, they are a good test of your product’s durability and resilience. Rigid-flex circuits hold up to these tests well, maintaining their quality even when subjected to extreme conditions.
A rigid-flex circuit board is better suited for high-volume production runs. It requires specialized fabrication equipment and expertise, so it is not as suitable for low-volume production or prototyping. However, by working with a company that specializes in these types of circuits, you can ensure the best results for your project.
Whether you’re designing a rigid-flex circuit board for your own use or are looking to incorporate it into an existing product, you should always consult with a manufacturer calculator to get an estimate of the manufacturing cost and time to market. PCBway has a detailed calculator that can give you an idea of what the final price will be for your specific design.
