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Thin PCBs—these are not your ordinary Rigid circuit boards of Flex PCBs. Thin and Ultrathin PCBs need to fit electronic devices which are becoming smaller and smaller in size. Since the manufacturing technology needed to produce Thin PCBs is advanced, you can only trust the industry leader—PCBMay.

• As thin as 0.1mm Flex PCB (Ultrathin)
• Enable wireless power harvesting (WPH) using Radio Frequency (RF)
• Compatible with IC for NFC enabled devices
• Suitable for an advanced medical wearable devices (e.g. sensors with IoT)
• Can choose Thin PCB with soldermask or without solder mask

Rigorous quality checks characterize our manufacturing process for our Thin and Ultrathin PCBs. We adhere strictly to the measurements for these PCBs. Unlike normal PCBs which are 0.8mm to 3.2mm, our thin PCBs are 0.4mm (for 4L Thin PCB), 0.2mm, and 0.1mm (for the Ultrathin PCB variant).

Every Thin PCB that comes out of our production line undergoes AOI and E-test to name a few Quality Assurance methods. Not only that, we are open to third-party audits in case you need it. We believe you deserve the finest PCB product available. Without any doubt, our PCB fabrication process is of the highest level.

We can also boast of our professional engineers and salespersons. Our engineering people will take care of your technical questions within an hour or so after inquiry. Meanwhile, our salespeople instantly respond to your inquiry any time you call, at your most suitable time.

Come to think about it, why not call right now? Let’s get started with your Thin PCB order.

Thin PCB: The Ultimate FAQ Guide

With the rapid growth of electronics, printed circuit boards (PCBs) have become more elevated and exact. Thin PCBs are a particular variety of PCBs manufactured of flexible materials and with great accuracy.

Thin PCBs are developed to comply with highly advanced technology such as rocket technology and other advanced technology. Flexible materials power the thin flexible PCBs to comply with the compact places.

Probably you are keen to know more about ultra-thin PCBs. You will find the answers about the thin printed circuit boards that come into your mind if you read the entire article.

What Is Thin And Ultra Thin PCB?

A thin PCB or thin-film PCB is a PCB that is thin in physical structure. Thin PCB is highly reliable and flexible to fit in compact places. It is made of polyamide or polyester thin film. That is why it is also known as thin-film PCB.

They are lightweight, thin in thickness, and have a high wire density. Because of its excellent bending or flexibility feature, it is more dependable and high-grade. The development of high-precision boards makes it possible to accomplish tasks that are otherwise impossible to do manually.

Thin PCB

But the thin flexible PCBs or thin PCBs can comply with the auto-detection technology. It helps in bulk production because it can meet the requirements of production feasibly.

Thin PCBs are primarily used in high-frequency and high-speed electronics, such as space rockets, communication, etc.  Its primary materials are known for their excellent dependability and fantastic flexibility and adaptability.

A thin printed circuit board (PCB) circuit board may be twisted or even folded completely. They are lighter in weight, more compact in size, more heat-dissipating, and more efficient than their predecessors in the industry. Moreover, the materials are insulating, sticky, and conductive.

What Are The Characteristics Of Thin PCB?

Thin PCBs have the following qualities because of their high precision technology and more adaptability.

• It needs a short assembly time since all lines are configured in pre-built.
• It avoids the need for redundant cable wiring.
• They are small in size. Their compactness reduces the size of the electronics as well. This compactness also increases the convenience of carrying.
• Thin-film PCBs are lighter than typical PCBs. The lightweight also keeps the weight of the final products.

Thin PCBs Ar Lighter In Weight

• The most significant characteristics of thin PCBs are thickness. This is the ultra-thin thickness that the name comes from. Their thin thickness improves the softness and bending capabilities of the boards. Which strengthens and intensifies the tri-dimensional assembling.

What Are The Design Steps Of A Thin PCB?

Even though they are high-frequency boards, the design processes for thin PCBs are the same as those for other conventional PCBs. To create an excellent thin printed circuit board, you must follow the design procedures outlined below.

Designing The PCB

The very first step of making a thin PCB is designing the schematic and layout of the PCB. Schematic is the outline or blueprint of PCBs. It shows the PCB’s shape, size, and component placement.

The Schematic also determines the layers of the thin PCBs.

PCB Layout

You have to use computer PCB design software to design the layout. On the other hand, you have to design the PCB layout based on the schematic design. For this,  you need to import the schematic file into your layout design software.

Making Thin PCB Board

Making the PCB board is one of the most vital parts of thin PCB designing. Since you cannot use typical rigid material to form the board, you have to give more attention here. Make a thin PCB board from thin-film materials.

Printing The Layout

Now, the time is to print the layout on your thin board. There are various options to print the layout on the thin boards. High pressure and high heat will generate the printing process.

Conductive Traces Etching

Etching conductive traces is another vital part of thin PCB design. Traces are the conductive paths that flow electrical current through the PCB components. Chemical etching and 3D etching among the etching process of the thin PCB board.

This video will show you how to etch flexible PCB traces.

Component Assembling

The final step of getting a final output of thin PCB is component assembling. Now you need to assemble the thin PCB with the necessary components. Proper component placement is the precondition of getting the peak performance from the PCBs.

You can use different types of components placement technology such as press-fitt, through-hole technology, and surface mounting technology. After successfully assembling the components, your thin PCB is ready to roll.

What Are The Benefits Of Ultra Thin PCBs?

Ultra-thin PCBs have several benefits when you use them for your electronics. The following are the benefits you will get by using thin PCBs.

• They are highly robust. They can fulfill millions of flexible cycles. And during the transition cycle, flexible PCBs preserve the quality of the materials.
• They use less costly materials such as copper. So the material costs remain minimal. And this reduces the total cost of manufacturing thin circuit boards.
• Thin-film PCBs are compatible with highly advanced technology such as rocket, space, and laser direct imaging. Implementation with care, these advanced technologies will not hamper the thin PCB boards.

Thin Film PCBs Are Compatible With High Technology

• Polyamide covering on the thin flexible PCBs is used for conductors. The polyimide offers dielectric and harsh condition protection.
• It is feasible to construct bespoke repeating transmit patterns on a thin printed circuit board. Each circuit increases the reliability of the system. Because of their reliability, thin PCBs will see a significant reduction in the frequency of service calls.
• Vibration and acceleration caused by the decreased mass of the thin boards might influence the joining and soldering of the boards. Thin PCBs with high ductility provide stability for the vibration and acceleration of the PCBs.

What Materials Are Utilized In The Fabrication Of Thin PCBs?

The thin base materials for the thin PCBs can make them possible to give a thin and flexible structure. The materials that are specifically used for the production of thin PCBs are briefly explained as follows.

• Polyamide and polyester: Polyimide, polyester, and other coatings are used to provide more protection to PCBs without enhancing the board’s thickness and weight. Polyimide has excellent temperature stability as well as solid performance. Polyimide provides more excellent thermal cycle stability while exhibiting less expansion.

Polyimide Is Used In Making Thin Flexible PCBs

• Copper Layers: When fabricating thin PCB boards, the demand for more copper is eliminated. The PCBs just need a copper foil with a lower coated copper content to fill in the connections.

In exchange for utilizing less copper, more spaces and lines are generated. Thin copper layers also result in reduced connector footprints as a result of their lower thickness.

• Glue: Thin printed circuit boards (PCBs) rely on high-quality adhesive to hold their components together firmly. The glue connects the numerous bending sections of the PCBs, allowing them to endure the flexibility of the circuit boards.

What Are The Applications Of Ultra Thin PCBs?

Thin-film PCBs provide a solution where you can not use typical rigid PCBs for applications. Unique design solutions and flexibility ensure thin printed circuit boards for a vast area in the electronic industry.

Heads-up displays are mostly used in the aerospace and medical sectors. It is essential to ensure the vision of pilot fields by not moving the heads away from the pilot console. Thin flexibles PCBs power-ups the heads-up displays.

Wearable Devices In Medical Sector Use Thin Film PCBs

Medical sectors use thin flexible PCBs to power up hearing wearable devices. The hearing devices that use flexible PCBs provide a hearing resolution range between 125 Hz to 10,000 Hz. One of the objectives of thin PCBs is to replace the wiring harness.

Besides these, thin flexible PCBs can be used diversely in electronics as follows.

• Sim cards are tiny electronic devices that allow you to communicate with others.
• Laptops, cellphones, cameras, and calculators use flexible PCBs
• Robotic arms, sensor devices, processing machinery, and bar code equipment are all examples of what is available with thin PCBs
• Anti-lock brake systems, airbag systems, and GPS systems are examples of advanced technology that uses thin printed circuit boards.
• Pacemakers and cardiac monitors are examples of medical devices.
• Resistors, satellites, and capacitors are types of electronic components.
• Tower lighting, LCD manufacture, and a motion system are all examples of using thin PCBs.

What Are The Structures Of 2 Layers And 4 Layers Of Extra Thin PCB?

Even though ultra-thin PCBs are far lighter than traditional FR4 PCBs, the layer structure of multilayer thin flex PCBs is simpler than conventional FR4 PCBs.

Ultra-Thin Flex PCB

We’ve included the structural layer of a 2layer and a 4layer thin PCB in this section for your convenience.

2 Layer ultra-thin PCB layer structure:

Four-layer ultra-thin PCB layer structure:

What Are The Types Of Thin PCBs Available?

Like conventional PCBs, there are different types available of thin PCBs. In terms of layer number and PCB combination, there are three types of thin film PCBs.

I. Single Layer Thin PCB

A single conductive copper layer is present on the surface of the single-layer thin flexible PCBs. The copper layers are joined together using an adhesive between two insulating polyimide layers. Adhesive construction for a single layer flex PCB runs between ½  and three mils in thickness. In contrast, the standard copper thickness ranges from ⅓  oz to 2 oz.

The standard thickness of polyimide cover lay is similarly ½  mil to 2 mils, as is the thickness of epoxy or acrylic glue, which is likewise 12 mil to 2 mils.

II. Double-Sided Thin PCB

There are two conductive copper layers in a double-sided thin-film PCB. These two conductive layers are joined with two internal and external polyimide insulating layers. Plated through-holes provide connections between the layers. The main configurations of a double-sided thin printed circuit board are single-sided access, double-sided access, and castellated holes.

Double-Sided Thin Flexible PCB

The standard thickness of a double-sided thin printed circuit board varies as like the single-sided one.

III. Multilayer Thin PCB

At least three conductive thin layers construct a thin multilayer printed circuit board. The layers could range up to 100 or more than that. Each flexible conductive layer is placed between two internal and external insulating polyimide layers. The core material thickness and cover lay thickness vary as per the single-sided one.

What Is The Importance Of The Thermal State Of Thin PCBs?

Thermal conductivity and stability for the thin PCB materials are the most important segment when choosing PCB substrate for your thin flexible PCBs. Different thermal states define the other forms of polyimide materials.

Glass Transition Temperature- Tg

When exposed to a specific temperature, PCB materials become softer. The substrate returns to its usual condition when the temperature has been removed from it. The temperature range between these two points is referred to as the glass transition temperature for the materials.

In terms of performance at high temperatures, polyimide is an excellent material to use. Polyimide has a glass transition temperature ranging from 400 to 500 degrees Celsius.

Decomposition Temperature

Decomposition occurs when a PCB material is subjected to a higher temperature than its melting point (Tg). By this point, the material has lost around 5% of its overall mass. The temperature range in which this occurs is referred to as the decomposition temperature range.

Effect Of Decomposition Temperature Is Permanent On Substance

The impact of decomposition temperature on the material is permanent in all cases. Temperatures in the breakdown range of polyamide are in the vicinity of 500° C. It is very beneficial to the material’s overall performance.

Coefficient Of Thermal Expansion

When the Tg of a PCB material is exceeded, the materials begin to expand due to the influence of decomposition temperature on them. The coefficient of thermal expansion (CTE) measures how quickly a substance expands when exposed to heat.

The CTE concentrations are typically between 10 and 20 parts per million (ppm). Hughes recommends a range of 70 parts per million (ppm).

Why Does Thin PCB Trace Corrosion Happen?

PCB trace corrosion is the process of oxidation of the conductive traces of thin PCBs. Many entities like air, humidity, moisture, water or electrolyte, etc., drive the copper traces of the PCBs to corrosion.

There are different particular reasons behind the trace corrosion of PCBs. These are as follows:

Electrochemical Corrosion

This sort of corrosion affects the electrical connections between components and the traces on printed circuit boards. When moisture or another liquid comes into touch with the electrical contacts and traces, corrosion occurs.

Galvanic corrosion and electrolyte corrosion are the two basic types of electromechanical corrosion. PCBs exposed to industrial applications, excessive moisture, etc., are most susceptible to electromechanical corrosion.

Flux Residue Corrosion

Soldering can expose your board’s metal to corrosive substances such as chlorine and other leftovers previously present in the flux compounds. When you’ve finished soldering, you’ll need to remove any leftovers.

Clean PCB After Soldering To Avoid Flux Residue Corrosion

It is not possible to decompose the leftovers when using wave soldering.  Because the temperature generated is not high enough, any residual flux residue must be avoided at all costs because it is acidic and highly corrosive.

How To Prevent The Trace Corrosion Of Thin PCB?

Corrosion prevention is not nearly as difficult as you may assume. If you want to avoid corrosion on your narrow PCB traces, a conformal coating would be the most effective and least complicated approach.

Rugged methods of preventing corrosion and oxidation include surface finishing, epoxy lamination of metal parts, solder mask application, and aerosol spraying of metal parts. The coating you choose should comply with the high temperature and moisture. But, it is necessary to assess the required one in the particular case.

Use Epoxy Lamination For Coating To Prevent Corrosion

Your knowledge and expertise will guide you in determining where to apply the coatings. And, in many cases, you will not be able to pinpoint the particular spot where the corrosion is occurring. As a result, laminating all exposed metal portions of your thin PCBs is a safe practice.

What Is EMI, And Why Should You Avoid EMI On Your Thin PCBs?

EMI is an abbreviation for Electromagnetic Interference, which may occur in electronics when exposed to an electromagnetic field. More specifically, it is a radio frequency disturbance. Devices containing electrical circuits, particularly those with printed circuit boards (PCBs), are in the danger zone of EMI.

EMI Drives PCBs To Destruction

You should avoid the EMIs to your thin PCBs because EMI is dangerous for electronics, and it is also costly to recover. EMI disturbs the radiofrequency, which interrupts communication and signals. So, the expected result may not come. Also, it is harmful to health.

For example, EMI can affect medical equipment such as ventilators, ECG monitoring, cardiac monitoring, pacemakers, etc. When they happen, it might be destructive.

What Should You Ensure While Designing Traces On Thin PCB?

To avoid any interference and effect on the performance of the traces, you should consider the following facts to design conductive traces on thin PCBs.

• Avoid angles of 45 to 90 degrees while tracing and installing other components and vias. Because impedance varies at 45-degree angles, EMI occurs.
• When installing, keep the low-speed and high-speed traces separate. Additionally, keep analog signals distinct from digital signals.

Keep Low-Speed And High-Speed Traces Separated

• Maintain short grounding return pathways. Long pathways cover a great deal of ground, and interference occurs.
• Drill and utilize the vias with caution as a result of the inductance and capacitance generated by vias. Additionally, the trace length would be prolonged if vias were used. Attempt to use as few vias as feasible.

How To Place The Components On The Thin PCB?

Component placement is one of the most vital parts of PCB assembling. You should keep the following facts in your mind during the component placement. These will help you to get the peak of the performance and avoid any interference of components on your thin PCBs,

• Always place the analog and digital components from each other. This will avoid cross-talk. Implementing shielding, coating, and multilayer will help to keep the components separated.

Keep Analog And Digital Components Separated

• Like components, also keep separate the analog and digital circuits from each other. Analog circuits carry high currents that cause problems for high-speed traces.

This video shows how to place components on a PCB:

What Are The Common Issues Of High Heat In Thin PCBs?

Excessive heat can create many negative issues if generated in thin PCBs. Extreme heat can cause the following problems on PCB:

• Excessive heat can destroy the PCB integrity. PCB substances and layers are sensitive to heat. When they are exposed to high temperatures, the structural state of the PCBs could be changed.
• Excessive heat also disrupts the circuit lines. Circuitries are changed in shape and susceptible to frequency change and signal interruptions.

High Heat Can Disrupt The Circuit Lines On Flex PCBs

• With high temperatures, the incompatible expansion of materials will happen. It drives the thin PCBs to the damages. With high heat, conductive and dielectric layers will misbehave due to different materials.
• High heat drives the PCBs’ metal parts to oxidation. The metals will be destroyed as a result.

How Can You Prevent High Heat In Your Thin PCBs?

There are many ways to keep reducing excessive heat on your thin PCBs. And it is a must to reduce the high heat to protect your boards from destruction. The following are some practical ways to reduce high heat.

• Keep high-speed and low-speed signals and digital and analog components separated.
• Utilize high-grade materials and components. High-quality parts are highly compatible with high heat.
• Proper coating and laminations are some of the most robust ways of heat dissipation.

How To Calculate The Thickness Of A Thin PCB?

Several factors determine the thickness of a printed circuit board. Copper thickness, trace thickness, dielectric thickness, soldermask thickness, and so on are all included in this category.

You may use a trace width calculator to determine the necessary thickness of your thin PCB. After entering all of the essential information, the calculator will provide you with an accurate answer for measuring the PCB thickness.

It is necessary to consider copper thickness, solder mask thickness, dielectric thickness, etc. To guarantee that specifications are met, you may calculate down to the hundredth of an mm in precision.

What Factors Should You Check While Choosing A PCB Manufacturer?

All things will go wrong when you get a faulty unit of production of your thin PCBs. And to get a quality production of PCBs, you must need a highly experienced and qualified PCB manufacturer.

So, what to look at a PCB manufacturer to consider them as a good PCB manufacturer?

There are several features as signs for a good PCB manufacturer. You should check for the following features.

• IPC certification.
• Quality management.
• Bulk production ability.
• Deadline meeting capability.
• Use of quality parts and materials.
• Vast experience in the sector.

Conclusion

Thin PCBs are generally high-grade PCBs. You need to know more about them before going for production. A highly experienced PCB manufacturer can help you in all ways to get the best products.

So, when you think about your thin PCB production, you could take the manufacturing service from PCBMay. PCBMay is one of the leading.