Rigid Flex PCB Manufacturer
Rigid-flex PCBs combine the best of both worlds: flexible circuits and rigid boards. These flexible conductive copper circuits can be designed to fit into tight or unconventional spaces inside electronic devices, while their rigid counterparts provide the structure and stability necessary to protect components and ensure proper board layout. In addition, they can make it easier to connect components with their corresponding connectors.
The production process for a rigid flex pcb manufacturer requires specialized equipment and materials, so they are typically more expensive than traditional rigid PCBs. However, for high-quality designs that require the flexibility of a flex PCB, the increased performance and reliability offered by this technology can be well worth the investment.
A rigid flex PCB can have either a single or double-sided flex circuit embedded between two rigid sections of the board. The layers of the flex circuit are clad with copper using either laminated or adhesiveless etch-and-plate (PET). This is followed by the same drilling, etching, and plated through hole (PTH) processes as for rigid boards. The flex portion of the board is then cut using one of several methods including laser cutting, CNC knife cutting, or punch and die sets.
How a Rigid Flex PCB Manufacturer Handles Small-Volume Production
For large-volume production, a hydraulic punch and die set is used to create the final flex board shape. This method has relatively high tooling costs, but it allows the flex circuit to be fabricated in batches, reducing per-unit manufacturing costs. For prototypes and low-volume runs, a blanking knife is used to cut the flex circuit. This is a long razor blade bent into the shape of the flex circuit outline, and it has the same effect as the punch and die set.
If you choose to use a blanking knife, it is important to make sure that all traces are designed with sharp radius bends. This will reduce the likelihood of smudging the copper during bending, which can cause them to break away from the polyimide substrate. It is also important to place all conductive copper on the flex layer and avoid placing any non-conductive materials on the flex layer, such as solder mask or thermal pads.
In addition to the aforementioned fabrication steps, rigid-flex circuits can be finished with a variety of special features, including metallization and surface finishes. These add a touch of elegance and protection to the product, and can make it stand out in the market. Adding metallization on the flex circuits can increase current carrying capacity and reduce resistance, while surface finishes such as gold and nickel will improve signal transmission. Finally, EMI shielding can be added to the flex and rigid sections of the board.
Choosing the right manufacturer for a rigid-flex board is crucial to its success. Ensure that they are capable of handling the fabrication and assembly of the flex circuits, and that their tools and facilities meet the required specifications. A good rigid-flex manufacturer will be able to answer any questions you may have and offer advice on the design and fabrication of your PCBs.
