Flex PCB Supplier Differ From PCB Fabrication
In general, flex circuits can be more costly than rigid PCBs to fabricate. This is because a flex circuit requires many additional steps for manufacturing. These extra steps can result in increased labor costs and material costs. However, a flex circuit can also offer cost savings when it is designed with features that reduce the need for cabling or connectors. These resulting cost savings can offset initial fabrication costs. The flexibility of a flex circuit can also provide benefits in assembly and integration compared to separate cable assemblies and connectors.
The most common base raw materials used in a flex pcb supplier are polyester (PET), adhesive Polyimide (PI) and adhesiveless PI. These materials are chosen based on their blend of advantageous electrical, mechanical and chemical properties. These materials can withstand high temperatures and are resistant to radiation and UV exposure.
Besides the copper foil, a flex PCB has two outermost insulating PI layers. These are the equivalent of the solder mask layer in regular PCBs. Additionally, each copper layer can contain Microvias that are plated through to make them conductive. The PCB fabricator can stagger these holes to mimic the blind and buried vias found in standard rigid PCBs.
The final step in the fabrication process is cutting out the flex circuits, which is called “blanking.” For high-volume production, this can be accomplished using a hydraulic punch and die set. This involves fairly high tooling costs. For low-volume runs, the flex circuits are cut out with a blanking knife that is similar to a long razor blade bent into the shape of the flex circuit.
How Does Flex PCB Supplier Differ From PCB Fabrication?
Depending on the design, a flex circuit may require stiffeners to help stabilize it. Selected areas of the flex circuit need to be rigid in order to prevent them from bending, for example, areas with connectors or mounting holes. The stiffener can be made from FR-4 or Kapton. Choosing the right one is important as it affects the overall thickness of the flex circuit.
A flex circuit can have up to 12 layers. It can also have hashed ground planes on either side of the signal layers for noise reduction. Additionally, a flex circuit can handle up to 5kV.
A flex circuit is often used to connect components like LEDs, LCDs and switches. It can also be used to replace traditional wires and connectors. This will reduce wiring costs, simplify the assembly process and increase reliability. The flexible structure of a flex circuit can also improve shock resistance and vibration isolation.
This can be particularly important for automotive and aerospace applications. As a result, a flex circuit can help to reduce costs and improve the performance of vehicles, aircraft, satellites, and other equipment. In addition, a flex circuit can allow a manufacturer to fit more electronics into a smaller space. This can be especially beneficial in the automotive industry where space is limited. It can also help to lower maintenance costs, reduce weight and improve vehicle safety.
