Flexible electronics, also known as flexible circuit boards or Flexible Printed Circuit Boards (FPCs), have transformed the electronics industry. These new elements are built and used to bend, twist, and fold which makes them suitable for novel and cutting-edge devices where the mass of parts and space is at an utmost limitation. PCBasic focuses on high-standard manufacturing of flexible circuit board types, serving a wide range of industries, including consumer electronics to medical devices.
This article will provide a detailed overview of flexible circuit boards, including the material, advantages, and manufacturing process. Also in this article, we will showcase the professionalism of PCBasics, and how that professionalism will result in a better PCB build.
What is a Flexible Circuit Board?
A flexible PCB is a kind of printed circuit board (PCB), which is made of flexible materials such as polyimide or polyester. In contrast to conventional and rigid PCBs, these PCBs can take on different shapes and can easily fit into crushed and small spaces. This edge makes it increasingly attractive for modern electronics applications like smartphones, wearables, aerospace technology, etc.
Commonly used materials in flexible circuit boards include a thin insulating polymer film, conductive copper traces, and protective coatings. Their unique design enables them to move dynamically, thus minimizing the need for connectors and wires, simplifying assembly, and improving reliability.
Flexible Circuit Board Material
The majority of the performance of a flexible circuit board will be based on the materials used. So, here are the three biggest materials:
Polyimide (PI): With great heat stability and mechanical strength, polyimide is well known for being the most common Flexible PCB material. High temperatures resistant, suitable for demanding applications.
Polyester (PET): PET is an inexpensive, excellent material with good electrical properties. However, it exhibits less thermal resistance than polyimide, and hence not very useful in high-temperature applications.
Liquid Crystal Polymer (LCP): An excellent choice for high-frequency (5G) devices due to their low dielectric loss and high moisture resistance.
PET vs. PI vs. LCP
The right material is very critical for flexible circuit boards. Here’s a closer look at the three materials:
Polyester (PET)
Polyester (PET) is a cheap material that is used in a lot of low-cost and low-performance applications.
Key Properties:
1. Thermal Resistance: Capable of working up to approximately 105 °C
2. Mechanical Strength: Offer decent flexibility but relatively low durability.
3. Electrical Properties: Applicable for Low-Frequency Applications
4. Moisture Resistance: PET can take up higher amounts of moisture than PI or LCP.
5. Price: Cheapest of the three materials.
Advantages:
Easy to find and did not cost a whole lot.
Flexible enough for simple applications.
For consumer electronics with moderate heat requirements.
Disadvantages:
Minimal resistance to thermal and chemical exposure.
Low application frequency is not recommended.
Does not work well under high-temperature applications.
Applications:
Cheap electronics: Calculators, TV remotes, etc.
Polyimide (PI)
Strong thermal and mechanical properties made polyimide the most widely used flexible circuit board material.
Key Properties:
1. Thermal Resistance: Up to 260 degrees Celsius maximum operating temperature.
2. Mechanical Strength: Very strong and elastic.
3. Electrical Characteristics: Suitable across the varied frequency spectrum.
4. Moisture Resistance: While PI is sensitive to moisture absorption, it will work well in most environments.
5. Cost: Moderate.
Advantages:
Outstanding thermal stability.
High mechanical strength.
Excellent mechanical flexibility.
Disadvantages:
Higher cost.
Absorbs moisture.
Applications:
Automotive and aerospace systems.
Scientific instruments and industrial machinery.
Liquid Crystal Polymer (LCP)
LCP is a high-performance material with excellent electrical and moisture resistance properties.
Key Properties:
1. Thermal Resistance: Up to 240°C maximum operation temperature.
2. Mechanical Strength: It is flexible, but a little bit stiffer.
3. Electrical: Good electrical properties; low-dielectric loss for high-frequency applications.
4. Moisture resistance: LCP virtually does not absorb moisture, so it works excellent even in humid environments.
5. Price: Most expensive of the three materials.
Advantages:
High electrical performance for better efficiency in high-speed applications (5G, RF devices).
Highly moisture resistant & designed for rough conditions
Lightweight and durable.
Disadvantages:
Higher cost.
Limited availability.
Applications:
Hyper-frequency communication devices (5G antennas, RF modules, etc.).
Implants and other medical devices.
High-performance aerospace and automobile systems.
|
Material
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Thermal Stability
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Durability
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Flexibility
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Moisture Resistance
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Cost
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Typical Applications
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PET
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Up to 105°C
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Moderate
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Good
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Average
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Low
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Consumer electronics, such as remote controls and calculators
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PI (Polyimide)
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Up to 260°C
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Strong
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Excellent
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Good
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Medium
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Aerospace, medical devices, high-end electronic equipment
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LCP (Liquid Crystal Polymer)
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Up to 240°C
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Extremely strong
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Good
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Excellent
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High
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5G devices, RF modules, high-performance medical equipment
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Advantages and Disadvantages of Flexible Circuit Boards
While flexible boards have advantages, they have disadvantages as well. Let us go through them:
Advantages:
Space Savers: They can bend and fold, thereby fitting into small designs and systems.
Light-Weight: Ideal for portable and wearables
Stress Withstanding: It can withstand stress such as vibrations and is mechanically better than traditional and inflexible PCBs.
Lower cost: Fewer connectors and wires simplify the process.
Disadvantages:
Expense at first: Flexible PCB appears costly during the manufacturing process compared to rigid PCB.
Less breathing space for repairs: The repair operability of flexible circuits is much worse than conventional PCBs.
All the hurdles aside, the advantages of flexible circuit boards are far superior to the disadvantages.
Flexible Circuit Board Manufacturing Process
Flexible circuit boards are manufactured with very high precision. Here is a step-by-step guide:
Material Selection: Based on the application requirements PI, PET, or LCP material can be selected.
CAD: To enhance performance, design the layout of the circuit with CAD.
Copper Lamination: A thin layer of copper material is provided to the base material with heat and pressure.
Etching: In this stage the excess copper is to be removed to have the needed circuit pattern.
Drilling and Plating: Make vias and coat each layer with conductive material for internal connections.
Pre-Applied coverlay: Place an additional layer for going to protect the circuit against environmental factors.
Quality Assurance and Control: Test boards to ensure that they meet relevant standards and specifications.
PCBasic adopts the some of the best practices method for manufacturing quality surface mount printed circuit boards with advanced machinery and quality assurance systems.
Flexible Circuit Boards Applications
Almost all modern-day electronics aspire to use Flexible circuit boards due to their folding, bending, and fitting into compact spaces properties. These properties are not offered by the traditional and rigid PCBs.
Consumer Electronics: Flexible circuit boards are found in smartphones, tablets, smartwatches, and many other electronics. Such electronics tend to restrict the manufacturer however by using flexible circuit boards, these electronics end up being more portable and lightweight.
Medical Devices: In the field of medicine, flexible circuit boards are found in devices that usually have compact spaces. For example, hearing aids and imaging equipment. Another thing is that their toughness and ability to endure repeated flexing make them ideal for implants and wearable health monitors.
Automotive Systems: Flexible PCBs are used by the automotive industry in advanced driver-assistance systems and sensors. They are even resistant to vibrations and harsh conditions, making them reliable when incorporated into cars.
Aerospace and Defense: Flexible circuit boards are extremely crucial for aerospace applications whose size and weight are one of the top priorities. Satellites, drones, and avionics systems offer very high reliability in extreme conditions.
PCBasic's Flexible Circuit Board Assembly Service
PCBasic is a trusted name in the PCB industry that provides complete flexible circuit board Assembly services. The most comprehensive approach of any provider, our teams of experts work in partnership with our clients, utilizing state-of-the-art proprietary design and manufacturing methods that deliver solutions specific to the client's needs.
Why Choose PCBasic?
Professional Equipment: All work is done on commercial-grade tools to guarantee precision and effectiveness.
Quality testing: All product is quality tested.
Custom Solutions: Supports industries from automotive to medical devices.
Affordability: Cost-efficient product without compromising the quality.
Certifications: ISO 9001, ISO 13485, and other quality certifications.
Whether it's a few boards for prototyping or large-scale production, PCBasic will be the partner in flexible circuit board assembly.
Conclusion
Flex circuit boards are revolutionizing the electronics industry due to their capabilities. These advanced components are creating new opportunities in design and function—from smartphones to aerospace systems.
Here at PCBasic, we are proud to be at the cutting edge of flexible PCB technology. By adopting industry best practices and a focus on quality, we not only provide groundbreaking integrations, we help guarantee they are implemented to the highest standards. If you need a trusted company for your flexible circuit board supplier, reach out to PCBasic. Let us help you bring your ideas to life with cutting-edge PCB solutions.
