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Need flexible PCBs?
Need flexible PCBs? We at OurPCB are here to assist you. As a leading PCB board maker, we offer top-notch PCB Assembly services, including the design and production of flexible PCBs.
Our team of experienced professionals is dedicated to providing high-quality, reliable solutions to meet all your electronic needs. With many satisfied customers worldwide, especially in the USA, you can trust OurPCB to deliver exceptional quality and service.
Specialized In Multilayer And Rigid-Flex Technology.
Flexible Circuit Manufacturing & Assembly as well as multilayer flex and rigid-flex circuits and also provide SMT component assembly on these products.
- High Temperature &High Density Applications
- Quality assured with more Reliability & Durability
- Flexible PCB Lead time:Usually 5-6 days(depends on your special design)
| Specification | Flexible PCB Capability |
|---|---|
| Layer Counts | 1-4 Layers (Ultimate: 5-8 Layers) |
| Tolerance of Finger Width | ±0.1 mm (Ultimate: ±0.05 mm) |
| Min Distance between Pads | 4 mils (Ultimate:3 mil) |
| The thickness of Finished Product（Flex part，no stiffener) | 0.05-0.5 mm (Ultimate:0.5-0.8 mm) |
| Type of Surface Treatment | OSP HASL, Lead-free HASL, Immersion gold, Hard gold, Immersion silver, OSP |
| Impedance Tolerance: Single-Ended | ±5Ω(≤50Ω),±10%(＞50Ω) |
| Ultimate: Single-Ended | ±3Ω(≤50Ω)，±8%(＞50Ω) |
What is the Cost of Flexible PCBs?
On average, flexible PCBs can range from $0.50 to $5.00 per square inch for standard designs and materials. However, this cost is not fixed and can vary based on several factors. The factors that influence the price include necessary assembly labor, prevailing labor rates, and the time required for assembly. Additionally, overhead manufacturing expenses and the design complexity of the board play significant roles in determining the final cost. To get a more accurate cost estimate, please use our free quote form.
Flexible PCB cost Dependent factor.
Many criteria determine the cost of FPCBs, and we have highlighted the major ones below;
- Physical Size; A large FPCB means a higher price, and its calculation is a cost per square inch (FPCB measurement).
- Circuit Construction; It depends on the materials used and the number of layers and pads. An additional layer is costly, and quality materials plus more pads also increase manufacturing costs.
- Volume; a greater volume results in a high cost.
- Layers; Added circuit layers augment assembly costs; thus, if you’re comfortable with a single-sided FPCB, stick with it.
- Finishing; Almost always, a good finishing guarantees a long shelf life for FPCB. Therefore, it’ll be pricey.
- Number and size of holes; Since drilling small holes is tough, FPCB prices are higher. Not only that but more holes equal more cost.
- Flex Board types depend on layers, ultimately determining the price.
- Custom or unique specification; If you require added features on your FPCB, for instance, solder mask clearance, side plating, or contoured edges, you’ll pay extra.
How to reduce Flexible PCB cost?
Every manufacturer should have a flex PCB cost estimator list that helps lower FPCB costs.
- Keep flexible layers to a minimum; Usually, rigid laminates are more cost-effective than flexible laminates. You’ll lower the cost by reducing the number of layers in the flexible circuitry.
- Keep overall layers to a minimum; If you reduce the number of layers, the number of plies of flow prepreg you’ll need will also be low. Thus, the cost decreases.
- Limit controlled impedance requirements; incorporating all achievable impedance values might be tempting. However, if you consider the design’s cost-effectiveness, test and model the values your flex circuit board needs.
- The copper thickness can be flexible and about 1/3 oz.
- Finally, buy FPCBs in large quantities to lower the overall cost.
Flexible PCB Manufacturing Capability
| Category | Project Item | Normal Capability | Ultimate Capability |
|---|---|---|---|
| FPC Base Material（Adhesive） | ShengyiSF302：PI=0.5mil，1mil，2mil；Cu=0.5oz，1oz ShengyiSF305：PI=0.5mil，1mil，2mil；Cu=0.33oz，0.5oz，1oz | / | |
| Material | FPC Base Material（Adhesiveless） | SongxiaRF-775/777：PI=1mil，2mil，3mil；Cu=0.5oz，1oz Xinyang：PI=1mil，2mil；Cu=0.33oz，0.5oz，1oz Taihong PI=1mil，2mil；Cu=0.33oz，0.5oz，1oz Subang AP：PI=1mil，2mil，3mil，4mil；Cu=0.5oz，1oz | PI=1mil，2mil，3mil；Cu=2oz PI=1mil，2mil，3mil，4mil；Cu=2oz |
| Layer | 1-4 Layers | 5-8Layers | |
| The thickness of Finished Product （Flex part，no stiffener） | 0.05-0.5mm | 0.5-0.8mm | |
| Size of Finished Products（Min） | 5mm*10mm（Bridgeless）；10mm*10mm（Bridge） | 4mm*8mm（Bridgeless）；8mm*8mm（Bridge） | |
| Size of Finished Products（Max） | 9inch*14inch | 9inch*23inch（PI≥1mil） | |
| Others | Impedance Tolerance | Single-Ended：±5Ω(≤50Ω),±10%(＞50Ω) | Single-Ended：±3Ω(≤50Ω)，±8%(＞50Ω) |
| Impedance Tolerance | Differencial：±5Ω(≤50Ω),±10%(＞50Ω) | Differencial：±4Ω(≤50Ω)，±8%(＞50Ω) | |
| Tolerance of Finger Width | ±0.1mm | ±0.05mm | |
| Min Distance to the Edge of Finger | 8mil | 6mil | |
| Min Distance between Pads | 4mil | 3mil | |
| Minimum Laser Hole | 0.1mm | / | |
| Mechanical | Minimum PTH | 0.3mm | / |
| Min NPTH Tolerance | ±2mil(Ultimate+0，-2mil or +2mil，-0) | / | |
| Solder Bridge Min Width(bottom copper＜2OZ) | 4mil(Green)，8mil | / | |
| Solder Mask | Solder Bridge Min Width(bottom copper2-4OZ) | 6mil，8mil | / |
| Overlay Colour | White、Yellow（printed character: White） | / | |
| Surface Treatment | Type of Surface Treatment Selective Surface Treatment | OSP HASL, Lead-free HASL, Immersion gold, Hard gold, Immersion silver, OSP ENIG+OSP，ENIG+G/F | / |
Flexible PCBs: The Ultimate Guide
As the name indicates, flexible PCBs are easy to bend and fold. PCB manufacturers use flexible dielectric base materials such as polyimide or polyester films to design these PCBs. Also known as flex circuits or flexible printed circuit boards, flexible PCBs facilitate heat dissipation properly due to the thin dielectric substrate used in their construction.
You can bend, shape, wrap, or fold these PCBs into any 2D or 3D shape. These features make flexible PCBs perfect for use in several applications with compact space availability such as in medical and surgical equipment, consumer electronics, automotive and space industry, and smart wearable devices.
Due to their space-saving, lightweight, and durable nature, Flex PCB are incredibly useful in places where standard rigid PCB fail to accommodate. If designed and fabricated properly and with the right materials, Flex PCBs offer robust interconnections to sustain dynamic conditions for a long time.
How are Flexible PCBs Manufactured?
Flexible PCBs’ manufacturing involves several steps to form thin and flexible boards which are easy to bend, fold and shape. Here are the steps that complete the PCB manufacturing process.
Step 1: Fabricate flexible laminates by bonding copper to PI film
Step 2: Laminate coverlay and copper foil
Step 3: Drill holes for vias and through holes
Step 4: Electroplate holes to form conductive vias
Step 5: Image and develop photoresist for circuit pattern
Step 6: Etch away unwanted copper
Step 7: Strip photoresist and apply solder mask over bare copper
Step 8: Expose and develop a solder mask
Step 9: Cure solder mask and apply surface finish
Step 10: Punch or route PCB to final shape
Step 11: Print silkscreen legends and conduct electrical tests
Step 12: Singulation and packaging
Key Steps in the Flexible PCB Manufacturing Process
Design of board structure and layout using design software
This crucial step requires you to create a board structure and PCB laminate design through different design software. The choice of software depends on the project and the features required. Programs such as Xpedition, Altium Designer, and Cadence PCB Editor can handle challenges that come with flexible materials.
Determination and procurement of necessary materials
Once the design is ready, it’s time to procure all the necessary materials for flexible PCB manufacturing. The materials include base materials such as polyimide or polyester films, copper traces, coating layers and adhesives.
Specific flexible PCB design based on the intended application and customer specifications
While designing flexible PCBs, it is essential that you always remain in touch with customers to meet their and intended applications’ needs precisely. You need to take care of several things like printed board types, plating requirements, number of layers, type of materials used, design process, component placement, or any additional placement of electrical components.
Design verification and error checking
Another critical step during flex PCB manufacturing is verifying design and checking errors. This is important to meet specific functions and requirements of flex PCB. You may use several methods to complete this process such as automated optical inspection, electrical testing, DFM checks, in-design inner layers checks or quality inspection. All these verifications are essential to reduce overall production costs, streamline manufacturing, and minimize manufacturing delays.
Creation of Gerber files containing information for PCB fabrication
Creating Gerber files through PCB design software helps you store location data and the shape of every element in the PCB. Each PCB layer has a separate Gerber file. These Gerber files also help you to create stencils, perform DFM and inspect your board.
Cutting flexible single- and double-sided layers
Cutting out single or double-sided flex layers using a hydraulic punch and die set which is capable of punching many flex circuits at one time.
Drilling
Drilling holes is a crucial step involving either mechanical or laser drilling. You can also drill multiple plated flex substrates. Based on the requirements, you can either drill plated through holes, blind/buried vias, or micro vias. Proper drilling ensures optimal functionality and reliable connections in flexible PCBs.
Through-hole plating: this process ensures electrical conductivity in the holes through copper electroplating. That’s why this is a very crucial step. Make sure that you do at least 1 mil copper plating in through hotels to add mechanical support.
Etching of final outer layer copper patterns
In the outer layer etching process, the etch resist is removed to expose copper. After that, unwanted copper is removed through chemicals. Finally, you also need to etch away the solder plate. After all these etching steps, you get the required copper pattern on the outer PCB layer.
Application of solder mask and silkscreen
Adding a solder mask is another important step in PCB manufacturing. This preventive layer stops the solder from adhering to unwanted areas. Also, the solder mask covers all non-conductive areas. As solder masks block solder flow, they enable uniform electrical connections during the soldering process. Along with the solder mask, silkscreen printing is another critical step. Through silk screen printing, you can add graphics, marks, and logos to indicate details, placements, and polarity of the flex PCB.
Surface finish plating
After completing the flex PCB, you’ll need to do surface finishing of the PCB layer. However, the type of surface finish used depends on the cost-effectiveness of the project, durability, and RoHS compliance. Different surface finish materials include Electroless Nickel Immersion Gold (ENIG), Organic Solderability Preservatives (OSP), HASL, and LF HASL.
What are the Advantages of Flexible PCB Manufacturers?
Flexible PCB manufacturers have many advantages in comparison to traditional rigid PCB manufacturers, all thanks to the unique properties of a flex PCB. Some of them are:
- Standardized, large-scale automated production compared to rigid PCBs: automation of production is more pronounced and used in flex PCB manufacturing, all thanks to material properties and space efficiency. Owing to lower connectors and wiring harness requirements, flex PCB manufacturers realize the great benefits of standardization and economy of scale.
- Ability to provide rapid prototyping services: Flex PCBs are made of polyimide or polyesters. These materials can be rapidly mounted in different shapes. The use of 3D printing is also prominent in flex PCB manufacturing. Therefore, manufacturers can churn rapid prototypes as per customer requirements.
- Use of high-quality laminates like FR, Rogers, and Aluminum: Flex PCB manufacturers can customize the product by using high-quality laminates such as FR, Rogers, and aluminum, depending on requirements for electrical and thermal conductivity, durability, cost, and weight.
- Capability to manufacture highly reliable rigid-flex and HDI PCBs: Flex PCB manufacturers can produce high-density interconnected PCBs having high reliability, as the flex PCBs have space efficiency. More and more components can be packed in a small space and layers, leading to more functions in a single board.
- One-stop shop for PCB assembly needs: Manufacturers of flex PCB can cater to different requirements on a single production line, as the substrate is flexible and mouldable to customized shapes and sizes.
- Fast production and delivery times: Thanks to rapid production techniques available for flex PCB production, the delivery time of such PCBs from the shop floor to consumers has reduced a lot over time.
Why Choose OurPCB?
OurPCB is a renowned ISO:9001 certified manufacturer of flex and rigid-flex PCBs in China. We have a huge clientele (more than 2000) spread across the world, We are there for you in every step of PCB manufacturing and assembly. Having expertise in wiring harness and cable assemblies, our team always ensures to fulfill our customers’ needs at affordable prices.
Thanks to the flexibility, reliability, space efficiency, and low weight of flex PCBs, the demand for flex PCBs is growing in all industries. If you need any help related to your PCB requirements, contact us. Our team is there to guide you through the process.
Customer Reviews - Flexible PCB
- Author: Percival Bramley
Item: Flexible PCB
Review: The flexible PCBs from OurPCB are of excellent quality. They are durable and can be bent and folded into various shapes without any issues. Highly recommended for compact electronic designs. - Author: Eleri Tamsin
Item: Flexible PCB
Review: Great product with fast delivery. The PCBs were exactly as described and worked perfectly in our project. Customer support was also very responsive. - Author: Thorne Ashby
Item: Flexible PCB
Review: These flexible PCBs are fantastic for tight spaces. The quality is top-notch, and they are very reliable. Will definitely purchase again. - Author: Liora Pemberton
Item: Flexible PCB
Review: Excellent service and product. The flexible PCBs met all our specifications and were delivered on time. Highly satisfied with OurPCB's service.
Services Related to Flexible PCB Assembly
- PCB Assembly Services: Comprehensive solutions for assembling printed circuit boards.
- Quick Turn PCB Assembly: Fast and efficient PCB assembly to meet tight deadlines.
- High Volume PCB Assembly: Scalable solutions for large-scale PCB production.
- Flexible PCB Manufacturing: Specialized in manufacturing flexible PCBs for diverse applications.
- Low Volume PCB Assembly: Cost-effective solutions for small batch PCB assembly.
- Turnkey PCB Assembly: End-to-end services covering all aspects of PCB production.
- PCB Design Services: Expert design services to bring your PCB concepts to life.
- Rigid-Flex PCB Manufacturing: Manufacturing robust and versatile rigid-flex PCBs.
- PCB Prototype: Rapid prototyping services to test and refine your PCB designs.
- Rogers PCB: High-frequency PCBs ideal for RF and microwave applications.
- Aluminum PCB: PCBs with excellent heat dissipation properties, perfect for high-power devices.
- Metal Core PCB: Thermal PCBs with metal bases for effective heat management.
- High Tg PCB: High glass transition temperature PCBs for improved thermal performance.
- High Frequency PCB: Designed for high-speed and high-frequency applications, ensuring superior signal integrity.
- Heavy Copper PCB: Built with thicker copper layers for high current and enhanced thermal management.
- HDI PCB: High Density Interconnect PCBs offering advanced circuitry in a compact design for complex applications.
- Custom Cable Assembly: We offer a wide range of customized cable services, hybrid cables, and wire harnesses.
