Rigid Flex PCB

Rush PCB makes Rigid Flex PCBs for applications requiring a sequence of flexible and rigid boards. Based on the application requirements, rigid flex boards are typically made up of several layers of flexible substrates attached to or sandwiched between one or more rigid boards. The design of the flex substrates makes them continuously flexible, and if necessary, the manufacturing process can give them flexed curve as well to help with installation in a 3-D space.

Designing boards for a 3-D space to achieve greater spatial efficiency is a complicated process. It makes designing rigid flex boards a lot more challenging compared to designing regular rigid boards. Rush PCB designs rigid flex boards to allow them to roll, fold, and twist in three dimensions according to application requirements. Special formation techniques allow the flexible board substrates to achieve the desired final shape during manufacturing.

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Rigid Flex PCB Advantages and Capabilities

As a rigid flex PCB manufacturer, Rush PCB provides customers with combination boards consisting of a large variety of technologies. We offer complex multilayer rigid flex boards for commercial applications, and high-reliability mil-grade printed circuit boards for military and aerospace requirements.

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ISO Certificate
UL logo
ParametersOur Capabilities
Drill Size — Outer Layers6 mil for .062 thick board
Drill Size — Inner Layers3 mil laser drill HDI Boards.
Copper Thickness0.5 oz to 4 oz
Minimum Hole Diameter0.004”
Minimum Space/Trace0.002”/0.002”
Minimum Pitch0.35 mm for BGA
Copper to Board Edge0.010”
(Via to Rigid Flex Transition area .030″ required)
Coverlay Opening0.004”
Coverlay Web with Kapton0.006”

Rigid Flex PCB Applications

Several applications require the use of rigid flex PCBs. These include digital cameras, high-end cell phones, aerospace systems, and military weaponry. Medical applications are increasingly using rigid flex circuitry as these can significantly reduce the size and weight of devices such as pacemakers. The advantage of size and weight reduction also applies to military weapons and their control systems, as they increasingly move towards rigid flex circuitry.

This trend towards using rigid flex boards is increasing in consumer products as well. Not only do these boards help in maximizing the space and minimizing the weight of products, but they also eliminate several solder joints and fragile, delicate wiring. This improves product reliability to a great extent.

In fact, all advanced electrical and electronic equipment can benefit from rigid flex PCBs from Rush PCB. This includes automobiles, tools, machinery, and testing equipment. If you are not sure of the PCB technology that will best suit your application, you can give Rush PCB a call, and our experts can help you to decide whether you need a rigid PCB, flex PCB, rigid flex PCB, or HDI PCB.

Rigid Flex PCB Production

Rush PCB offers both prototypes as well as large scale production quantities of reliable rigid flex PCBs. We can even assemble them for you, as we are experts in this field. Our rigid flex PCBs are specifically good in overcoming weight issues in limited space, as they offer spatial degrees of freedom.

Your projects will gain significant benefits from using Rush PCB’s rigid flex PCB technology. You will be able to realize the benefits sooner if you make a careful and proper assessment of the options available to you at the early stages in the design phase of your project. Involving an experienced fabricator of rigid flex PCB technology such as Rush PCB early in the design process will make sure both the design as well as the fabrication remain in synchronous coordination to make the final product a success.

The above requirement of early association is necessary as the fabrication of rigid flex PCB is far more complex and time-consuming compared to producing regular rigid boards. The flexible components that go into the fabrication of rigid flex circuitry require totally different methods during the handling, etching, drilling, and soldering processes compared to that for regular rigid boards.

Rigid Flex PCB Fabrication Issues

While fabricating rigid flex PCBs, the flexible polyimide core shrinks after the etching process. Therefore, once the bonded copper foil has undergone etching for removal of unwanted copper, the size of the PCB reduces. Designers must take this shrinking into consideration during the early design phase of the rigid flex PCB.

If the application demands forming the flex portion of the PCB into a bent shape during fabrication, it requires individual lengths of several flexible substrates in the multilayer flex PCB to be of different lengths. Failure to account for the difference in lengths during early phases of design may lead to excessive stress in the PCB during the forming process, and this may even cause fracture of layers.

Rush PCB are experts in design, fabrication, and assembly of rigid flex PCBs. For any type of inquiry or help, you can call us at 1408 – 496 – 6013, and talk to our technical expert staff.

Rigid Flex PCB Benefits

  • Minimize your space requirements by considering 3-D in early stages of design
  • Reduce system weight and overall board size by removing the need for wiring and connectors between individual rigid PCBs
  • Lower the parts count in your BOM
  • Improve the product reliability by reducing solder joints on wiring
  • PCB assembly process is simplified and less error-prone
  • Easier to handle during assembly compared to totally flexible boards
  • Possibility of simplifying modular interfaces through integrated ZIF contacts
  • Possibility of complete testing prior to assembly, with simpler test conditions
  • Significant reduction in logistics and assembly costs
  • Possibility of improving mechanical design complexity for improving the degree of freedom leading to an optimum housing solution

To contact our PCBA team or request more information about Rigid Flex PCB services, please email us at sales@rushpcb.com or call us at 1 408-496-6013.

EXOTIC PCB MATERIALS

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FLEX AND RIGID FLEX

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