Rigid Flexible PCBs
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Rigid Flexible PCBs

Rigid-Flex PCBs (Rigid-Flexible Printed Circuit Boards) combine the structural integrity of rigid PCBs with the design freedom of flexible circuits. This hybrid solution offers the best of both worlds—mechanical stability where needed, and dynamic flexibility where space or motion constraints apply.

Unlike traditional rigid or flex-only designs, rigid-flex PCBs are fabricated using a seamless combination of FR4-based rigid sections and polyimide-based flexible layers, integrated through a unified manufacturing process. This design enables both reliable component mounting on rigid zones and bending or folding in flexible regions—perfect for compact, complex electronic assemblies.

Rigid-flex boards are especially favored in harsh environments and mission-critical applications, making them ideal for the medical, automotive, and industrial control sectors.

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🔶 Key Advantages of Rigid-Flex PCBs

Rigid-flex PCBs bring distinct design and performance advantages compared to traditional designs:

  • 📦 Space & weight savings through 3D routing and the elimination of bulky connectors

  • 🔗 Higher reliability with fewer interconnects and solder joints

  • 🔧 Simplified assembly and testing, improving manufacturing efficiency

  • 🔌 Modular integration, allowing more efficient mechanical design

  • 📐 Supports complex mechanical layouts, folding structures, and dynamic bending

  • ⚠️ Note: The complexity of manufacturing leads to higher unit cost, longer lead time, and lower yield compared to standard PCBs.

🔶 Applications of Rigid-Flex PCBs

● Consumer Electronics

Rigid-flex PCBs are widely used in high-end electronics requiring compact form factors and flexible interconnects:

  • Foldable smartphones and tablets

  • Wearables and smart glasses

  • Laptop hinges and camera modules

  • RF communication modules

● Automotive Electronics

Ideal for integrating multiple functions in limited spaces, including:

  • Steering wheel control interfaces

  • Touchscreens and dashboard displays

  • Seat control panels

  • In-vehicle entertainment systems

  • Navigation and radar modules

● Industrial and Medical Equipment

Used to ensure reliable signal integrity, low impedance loss, and mechanical resilience across multiple connected boards in:

  • Surgical and diagnostic equipment

  • Industrial control modules

  • Robotic arms and sensor nodes

  • Aerospace-grade monitoring systems

🔶 Technical Specifications

Number of Layers 4 – 26 layers
Technology Highlights Mixed materials: RF, high-speed, standard FR4, polyimide
Adhesiveless or adhesive-based flex, with coverlay or flexible solder mask
Bending Performance From basic 90° bends to full 360° dynamic flex for continuous motion applications
Bend Features Bend radius depends on material thickness – thinner flex allows tighter bends
Materials RA Copper, HTE Copper, FR4, Polyimide, Adhesive
Finished Copper Weights 0.5 oz, 1 oz, 2 oz, 3 oz
Minimum Track / Gap 0.075 mm / 0.075 mm
PCB Thickness 0.40 mm – 3.0 mm
Flex Section Thickness 0.05 mm – 0.80 mm
Maximum Dimensions 457 mm × 610 mm
Surface Finishes ENIG, OSP, Immersion Tin, Immersion Silver
Minimum Mechanical Drill 0.20 mm