Also known as flex circuits or flexible electronics; they are thin and lightweight electronic circuits usually constructed with polyimide plastic substrate.

Traditional PCBs and Flexible PCBS serve the same purpose so many manufacturing components are the same. Similar tools and technology are used during fabrication and steps relating to the drilling of holes, printing and more apply to both boards. So which type you choose will depend on your application. When the total weight, portability or design space of a device is in consideration, a flexible circuit enables product manufacturers to configure electrical layouts in ways that rigid PCBs cannot.

Flexible circuits weigh less than rigid PCBs yet still offer the same reliability and durability. A lightweight and flexible circuit board can ensure that a smaller product doesn’t increase in weight during manufacturing. A typical flex may be only 100 microns thick whilst the thinnest viable rigid board is around 500 microns.

Flex provides several advantages to cables. We’ve covered the pros and cons of both in our article Flex Circuits Fit Where Cables Cannot. Flex’s higher upfront cost will dramatically reduce cost in the long run. Cables can take several weeks to go through production, while flex PCBs can be completed in several days. In short, using flex eliminates or completely decreases cable cost, reduces assembly time, and produces a lighter end-product.

Some flex materials, like Kapton, do not drill as well as regular materials. 10 mils and above is preferred for minimum size, only in the flex part. Rigid-flex specs are similar to rigid board specs. Pad size, plating process for flex is barrel-only (hole wall).

No-flow prepreg is the preferred bonding material for joining flex and rigid materials. This is most commonly found in standard FR-4 or Polyimide.

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