Flexible Circuit Technologies, design and manufacturing

Flexible Printed Circuits

Benefits

There are many benefits to flexible printed circuits as follows:

Assembly Error Reduction - With accurate designs and automated production, flex circuits eliminate human errors once involved in hand-built wire harnesses. With the exception of production-induced errors, circuits are ONLY routed to those points called for by the accurate design plan.
Decreased Assembly Time & Costs - Flex circuits require less manual labor during assembly and reduce production errors. Flex circuits have an intrinsic ability to integrate form, fit and function. Flex circuits eliminate the high cost of routing, wrapping and soldering wires. Complete interconnection systems are installed or replaced, rather than individual hard PC boards. As a result, wiring errors are eliminated and hence manufacturing costs are reduced. Whether it is a low volume production with a complex circuit or high volume production with a simple circuit, assembly time and costs are decreased.
Design Freedom - Unlike rigid boards, flex circuits are not restricted to two dimensions. Because they are as flexible as wires or ribbon cables, flex circuit design options are endless. At Flexible Circuit, we pride ourselves on taking on the most complex of design challenges. Flex circuits can be designed to meet highly complex and unimaginable configurations while being able to operate in the most hostile environments. Flex circuit designs could entail any of the following:
- Highly complex configurations
- Withstand hostile operating environments
- Single- Double- combinations
- Complex interconnections
- Shielding
- Rigid/flex capabilities
- Surface mounted devices

Double Sided with HASL Finish

Flexibility during Installation - Flex Circuits allow a third dimension to work with because they can interconnect between two or more planes during execution. As a result, they solve space and weight problems unmatched by rigid boards. Flex circuits can be manipulated many times during installation and execution without electronic failure.
High Density Applications - Flexible circuits allow for minutely narrow lines giving way to high density device population. Denser device populations and lighter conductors can be designed into a product, freeing space for additional product features.
Improved Airflow – Flex circuits, because of their streamlined design, allow for the flow of cooling air through an electronic application.
Increased Heat Dissipation – Due to the larger surface-to-volume ratio and compact design of flexible circuits, a shorter thermal path is allowed. Further, the thinner design of flex circuits allows for heat dissipation from both sides of the circuit.
Increased System Reliability - In the past, most circuit failures occurred at an interconnection point. Flex circuits can be designed so that interconnections are reduced, which in turn, increases a circuit's reliability.
Point-to-Point Wire Replacement - Depending on the number of point-to-point connections in a circuit design, at Flexible Circuit, we guarantee that we can design and build a single flex circuit that can eliminate many (if not all) of those interconnections. At Flexible Circuit, "We Go Where Others Will Not."
Reliability and Durability - In designs that have moving parts, the flexible circuit can move and flex up to 500 million times without a failure. The exceptional thermal stability of polyimide also allows the circuit to withstand applications with extreme heat. Polyimide excellent thermal stability provides a better base for surface mounting than hard boards. Because the compliant base film places less stress on soldered joints, thermal mismatch is less likely to occur.
Repeatable Routings - At Flexible Circuit, our circuits are made from precise replicas of artwork for superior manufacturing consistency. The etched circuits replace the solder and hand wiring connections of the rigid board, completely eliminating wiring errors.
Simplified Circuit Geometry - Flexible Circuit places surface mount electronics directly onto the circuit which results in streamlining the overall design. Intricate patterns that were nearly impossible to achieve with rigid boards are made easily in flex circuits.
Package Size and Weight Reduction - Multiple systems in rigid boards create more weight and utilize more space. Flex circuits contain the thinnest dielectric substrates available. Thinness allows for a more streamlined design, eliminating the need for bulky rigid boards. The elasticity and flexibility allow package size reduction. In addition to package size reduction, package weight reduction is another benefit. With the ever increasing demands of the electronics industries, weight reduction keeps flex circuits very competitive.

In summary, if you have flexible circuit design needs, Flexible Circuit can help. For more in depth information, click on the links below:

Overview	Benefits	Materials	Capabilities	Types
Advanced Features	Applications	Design Help	RFQ	Links