Your Best Flexible PCB Manufacturer

As one of the best flexible PCB suppliers, PCBMay has passed a lot of certifications like ISO9001, ISO14001, SGS, UL USA and Canada.

PCBMay is a great choice as your reliable flexible PCB manufacturer, we offer fast process and reply service when you send one inquiry, our experienced sales team will reply to your email within 1h and also provide a quotation with 1-2h depending on the flexible PCB easy or complicated.

PCBMay takes a fast turnaround delivery time for flexible PCB, the fastest lead time is 24h for the prototype of flexible PCB, the standard delivery time of prototype is 7-10 working days, the mass production of flexible PCB is 15working days.

We guarantee the lead time of shipment according to customer need, the quick turn cost will be required.

Flexible PCB: The Ultimate FAQ Guide

Printed circuit boards have been all around us for several decades but they have evolved with time; flexible printed circuit boards are one of the modern examples.

Despite their delicate look, flexible printed circuit boards are robust, efficient, reliable, and durable. In many cases, they are the most suitable type of board that can be used.

Without flexible printed circuit boards, many gadgets that we use today cannot be developed.

The bending ability of flex boards lays the foundation for several devices that are prone to frequent stress and harsh environmental conditions.

Flexible PCB

Moreover, flexible printed circuit boards are highly stable even at high temperatures.

In some cases, circuit development with flexible printed circuit boards is far more economical than with rigid printed circuit boards. But what are they comprised of

What is Flexible PCB?

Flexible PCBs are diverse in their designs and applications. The trend towards further expansion of their use is due to the great advantages that they create in interconnection technology.

They have now become a very attractive way to provide interconnections in modern electronic equipment.

Flexible Printed Circuit Boards (FPC) are:

1. Single-sided
2. Double-sided
3. Multilayer printed circuit boards manufactured on a flexible base of small thickness.

They serve as connections between various parts of electronic devices.

Flexible PCB boards also act as a replacement for cable connections. Sometimes flexible printed circuit boards serve as the basis for inductors, antennas, and many other devices.

A flexible PCB (flex PCB or flex circuit) is a printed circuit technology that consists of using a high-performance plastic substrate, such as polyimide  PEEK film. What’s more, flex circuits can be silkscreened with silver on polyester.

Flexible Printed Circuit Board

Assembly can be done with components used for conventional printed circuits while allowing the circuit to adhere to a specific shape or by bending in use.

What are Flexible Printed Circuit Boards Made of?

As the name implies, flexible PCBs are flexible circuits with bending ability, tensile strength, and fragile substrate.

They are often developed in complex 3D forms in a wide variety of applications. Flexible PCBs enable the production of development of circuits that cannot be developed on ordinary PCBs.

Moreover, flexible PCBs are lightweight, durable, and also economical in many cases.

Although flexible PCBs are primarily used in complex circuits that require bending PCB around the edge or attaining a 3D shape they are also used in low-tech applications.

For example, they are commonly used in under-the-counter LED lamps because they can simplify installation.

Since flexible PCBs are usually used in flexible products, there is a perception that flexible PCBs are used in only flexible products which is not true.

Many systems need flexible circuits instead of flexible use to fit into the equipment. Typically, low-cost electro-deposited copper is used in such static applications.

Flexible PCB Board Components

Flexible PCB Assembly

Flexible PCBs are comprised of the following materials.

• Conductors: They allow electrical signals to flow in the circuit. The commonly used conductor in flexible PCBs is copper. However, in some applications, materials such as aluminum, carbon, and silver ink are also used.
• Adhesives: For surface mount equipment binding, adhesives are used. It is utilized before customer specifications and conductor thickness. Epoxy, acrylic, or PSAs (Pressure Sensitive Adhesives) are commonly used adhesives. However, not all applications require adhesives; many flexible PCBs are developed without the use of any adhesive.
• Insulators: They are primarily used for isolating electrical conductors but sometimes used as support. The most common insulators are polyimide, polyester, solder mask, polyethylene naphthalene, and polyethylene terephthalate.
• Finishes: The finishing protects the board’s metallic surface against oxidation. The type of finish varies depending upon the application. The most widely used finishes are tin, nickel, gold, silver, and carbon.

What Types of Flexible PCBs

Although there is a slight variation in the design of different types of flexible PCBs their development varies greatly. Some of the most commonly used types of flexible PCBs are as follows.

Single-sided flexible PCBs

Single-sided flexible PCBs are developed with a single driver layer prepared on a flexible dielectric film with a metal polymer.

The holes in the base film are created to enable soldering the interconnection of components.

Single-sided flexible PCBs can be manufactured with or without protective coatings as cover layers. However, they are usually, a protective layer is used.

Double-sided Flexible PCBs

Double-sided flexible PCBs contain two circuit layers. The circuits can be manufactured with or without plated through holes, but the plated through hole variation is common.

The double-sided flexible PCBs developed without through-holes are defined as Type-5.

Double-sided flex circuits are developed with protective cover layers on either side of the completed circuit, depending on the design requirements.

Double-Sided Flexible PCB

One of the key benefits of this type is that it can be easily prepared for intersections.

Multilayer Flexible PCBs

The multilayer flexible PCB is a new division of traditional flexible PCBs.

Its development process involves a multi-step etching system, resulting in a flexible PCB with finished copper thickness varying in many positions over their length.

What is Multilayer Flexible PCBs

Flexible circuits with three or more layers are called multilayer flexible PCBs.

They can be made of several single-layer or double-layer flexible PCBs, bound together.

The layers in multilayer flexible PCBs are usually laminated but in applications that require extensive flexibility, continuous lamination is not considered.

Multilayer flexible PCBs are an innovative way of dealing with huge complex circuit designs that have to be laid in 3D positions.

Moreover, multilayer flexibility enables the designers to develop circuits with specific impedance requirements and minimal use of shielding equipment; leading to cost-reduction.

What are the Benefits of Flexible PCBs

Flexibility

Rigid PCBs are prone to breaking and malfunctioning when bent or exposed to vibrations, especially in 3D space.

With rigid PCBs, certain circuits cannot be developed reliably, and their longevity is also not guaranteed.

But since flexible PCBs can easily bend, fit in 3D positions and attain shapes, they enable the development of 3D circuits.

Moreover, they are easy to fit in 3D spaces since they do not break during fitting.

Lightweight

Apart from the flexible nature flexible another major benefit of flexible PCBs is their lightweight and compactness.

They are thin, light, and can easily be pinned, plied, and placed in areas where rigid PCBs cannot be housed.

Design Precision

On a commercial scale, most manufacturers develop PCBs on automated machines, but rigid PCBs can be developed manually too.

Since manually developed PCBs are prone to mistakes and malfunctioning, they are not highly reliable.

Whereas the flexible PCBs cannot be developed manually; they are developed only using automated machines which makes them highly precise and reliable.

Design Freedom

Since flexible PCBs are created layer by layer, the designers have more freedom to design each layer.

Moreover, the layers can be accessed from either side which enhances accessibility; leading to an improved design.

Compact

Flexible PCBs can be developed for both through-hole and surface mount devices.

Since the surface mount devices can fit in a short space and with flexible printed circuit boards complex circuits can be developed in short spaces.

The high density of components assembled on flexible PCBs helps fit huge circuits in tiny gadgets.

Thermal Stability

Since flexible PCBs are often developed with closely assembled surface mount devices it leads to excessive heat generation.

But the flexible substrates used in flexible PCBs such as polyimide have high thermal stability.

Which helps protect the circuit against excessive thermal conditions.

Flexible PCBs have better heat dissipation abilities than conventional types.

Improved Airflow

Since the flexible PCBs are developed and usually remain in 3D space, the components exist in different planes which enable better airflow.

The circuits thus remain cooler as compared to rigid printed circuit boards. The enhanced airflow also enhances the longevity of the circuit.

Reliable and Durable

According to some manufacturers, flexible PCBs are designed to flex up to 500 million times the average lifespan of the equipment it is being used in.

Flexible PCB

Since many flexible PCBs are capable of bending up to 360 degrees, they are highly resistant to breaking.

The high flex ability, low ductility, and volume enable them to withstand the impact of vibrations and shocks, thus improving their performance.

High System Durability

The interconnections have always been a challenge in conventional printed circuit boards.

They often cause malfunctioning and interrupt circuit performance.

Whereas with flexible PCBs, the circuits can be developed with fewer interconnections which helps improves circuit durability.

Streamlined Designs

The surface mount technology is not limited to just flexible PCBs. Surface mount devices can be assembled on rigid printed circuit boards but they are easier to mount on flexible PCBs.

This is why flexible PCBs in combination with surface mount technology have extensively simplified circuit development.

Suitable for applications with high temperatures

As already mentioned, flexible PCBs have high thermal stability and good airflow, they are suitable for high-temperature applications.

The substrate materials used in flexible PCBs like polyimides are highly resistant to high temperatures and materials like acids, oils, and gases.

Therefore, flexible PCBs can easily withstand extreme atmospheric conditions; temperatures as high as 400° C.

You will have a look at this video:

What are the Applications of Flexible PCBs

Flexible PCBs are widely used in certain applications both for circuit assembling and connections.

Especially where flexibility, area savings, and structural challenges limit the use of rigid circuit boards.

Moreover, flexible PCBs are suitable for movable parts in electronic equipment such as printer rollers and robotic arms.

Many gadgets such as cameras, calculators, and cellphones commonly contain flexible PCBs.

The robustness with elastic abilities and lightweight makes flexible PCBs a good match for gadgets and handheld devices.

Apart from these, flexible PCBs have certain applications in the automobile, medical, and aerospace industries.

Automobile Applications of Flexible PCBs

Flexible PCBs are used in the development of certain automobile parts such as panels, under-hood controls, and circuits that must be shielded.

Flexible PCB

Moreover, flexible PCBs are ten times lighter than an average cable harness which helps reduces the overall weight of automobiles.

Aerospace Applications of Flexible PCBs

Flexible PCBs are commonly used in aerospace products as their flexible nature matches the requirements.

One common example is the heads-up display (HUD) which enables the pilots to visualize enemy signals during flight.

The latest HUD model is a wearable headset that can create a 3D holograph of the target.

Flexible PCBs have played a vital role in the development of HUD hardware. Their flexible and lightweight features made it possible to create a wearable model of HUD.

Medical Applications of Flexible PCBs

Over the last few years, hearing aid devices have been extensively innovated and flexible PCBs are playing a vital role in this innovation.

Flexible PCBs have enabled the incorporation of a digital signal processing unit, microphone, and battery inside a tiny housing of hearing aid devices.

The technology has improved circuit design, enhanced frequency range; making hearing aid better than ever.

Sensing Applications of Flexible PCBs

Flexible PCBs are commonly used in sensors that are prone to extreme atmospheric conditions and frequent vibrations.

Many sensors are developed on flexible PCBs which makes them compact yet robust. Moreover, the development of such sensors is nearly impractical with rigid printed circuit boards.

Medical Applications of Flexible PCBs

Flexible PCBs have extensively evolved many wearable products such as fitness trackers, smart clothes, smartwatches, and medical equipment.

Today, with wearable medical sensors, one can track medical conditions, store data, and even communicate in real-time.

These innovations not only help analyze medical conditions but also makes it easier for doctors to stay informed at all times.

Most of the wearable sensors and medical equipment are developed with flexible PCBs as they are durable and reliable even under stress.

Flexible PCB

What are Important Features of Flexible PCB

Downsizing

Flexible PCBs use the thinnest dielectric base material available today for making interconnects.

In some cases, these materials can be used to make flexible PCBs having a total thickness of fewer than 50 microns, including the protective layer.

For reference, rigid mounting pads with the same functionality are twice as thick.

Not only is the thinness of flexible PCBs attractive in and of themselves, but the flexibility to fold it also allows for the reduction in volume and size of electronic devices.

Reduced Assembly Time and Cost

Flexible PCB represents a simple and fast interconnection technology for assemblies and electronics blocks. An alternative to flexible PCBs – wiring and flexible cables.

These are associated with the need to route wires along the intended paths of connections and their fastening, stripping, and soldering each wire separately. The wiring harness also requires additional labor to designate link addresses.

Flexible PCB(FPC) enables the use of group assembly and assembly methods. In addition, their production itself is much cheaper due to the use of group manufacturing and marking technologies.

Reduced Build Errors

While wiring is inevitably human error, flexible PCBs do not have human error sources. Manual assembly is a constant risk of errors.

Flexible PCBs (FPCBs) are designed as part of an interconnected system and then reproduced by machine methods to prevent human error.

As a result, with the exception of inevitable manufacturing errors, flexible PCBs do not allow for connections that do not match the designed circuit.