Rigid-Flex PCBs
Uniting Strength & Flexibility for Advanced Electronics
Rigid-flex printed circuit boards (PCBs) combine the features of rigid and flexible PCBs in a single, compact design. By integrating both rigid and flexible elements, these PCBs offer enhanced durability, space efficiency, and design flexibility that are essential for applications requiring high performance and reliability.
At HT Global Circuits, we specialize in rigid-flex PCB fabrication that meets the demanding requirements of several industries. As a leading rigid-flex PCB manufacturer, we provide comprehensive solutions for custom rigid-flex PCBs, offering quality, precision, and performance for a wide range of applications.
Rigid-Flex PCBs Capabilities
Our capabilities encompass a wide range of rigid-flex PCB fabrication solutions, from single-layer designs to intricate, high-layer configurations for advanced applications.
| Specification | Capability |
|---|---|
|
Number of layers |
4 – 16 layers |
|
Materials |
RA copper, HTE copper, FR-4, Polyimide, Adhesive, Low-loss dielectrics, and Ultra-thin copper |
|
Copper weights |
0.5 – 3 ounce |
|
Minimum trace length and spacing |
2.4 / 2.4 mils |
|
PCB thickness |
16 – 120 mils |
|
Maximum dimensions |
32″ x 52″ |
|
Surface finishes |
ENIG,OSP, Immersion Tin, Immersion Silver, Hard Au |
|
Minimum drill |
4.0 mils |
|
Special processes |
Counter sink, Edge platting, Bonding, Castelated holes, Carbon ink, Peelable solder mask |
|
Testing and Compliance |
100% electrical testing, IPC-6013 Class 3 standards, and dynamic flex testing under environmental stress. |
Certifications
Our production facilities produce in accordance with the IPC-A-600, IPC 6011 and IPC 6012 standards and have been awarded all the key certificates:
Beneficial Features of Rigid-Flex PCBs
Being an experienced rigid-flex PCB supplier, we provide advanced rigid-flex PCB solutions, integrating the durability of rigid boards with the flexibility of flexible circuits. These hybrid designs offer distinct advantages for compact, high-performance applications.
Comprehensive Layer Configurations
We offer a range of rigid-flex PCB configurations, including single- and multi-layer options, to meet various design needs. We can also provide complex stack-ups with blind/buried vias and controlled impedance (±8%) for demanding applications. This flexibility allows designers to choose the ideal layer structure, from simple designs to complex HDI circuits, ensuring precise control over electrical, thermal, and mechanical properties for any project.
Advanced Manufacturing Capabilities
We use advanced manufacturing techniques to produce high-quality rigid-flex PCBs with precision and reliability. These processes ensure strict adherence to industry standards, delivering products with tight tolerances, complex geometries, and precise layer registration for reliable performance in challenging conditions.
Customized Design Solutions
We offer custom rigid-flex PCB solutions tailored to specific project needs. This ensures each PCB is optimized for harsh environments, high reliability, or space-constrained designs.
Versatility Across Industries
Our circuit boards are versatile and used in diverse industries. They feature compact designs and robust durability to withstand extreme conditions, making them ideal for space-constrained applications, such as wearables, satellite components, and medical devices.
Enhanced Durability and Reliability
These boards combine rigid and flexible sections to withstand mechanical stress, vibration, and thermal cycling. The design allows flexible parts to move without damage, while rigid sections maintain structural integrity, ensuring high reliability and longevity in demanding applications.
Space and Weight Optimization
Rigid-flex PCBs reduce the size and weight of electronic assemblies by integrating rigid and flexible sections. This eliminates the need for connectors and multiple PCBs, making them ideal for space and weight-sensitive applications in industries like aerospace, medical devices, and consumer electronics.
Streamlined Assembly Process
Rigid-flex PCBs streamline assembly by integrating connectors into a single board, eliminating the need for separate interconnects. This reduces costs, complexity, and the risk of mechanical failure, resulting in improved reliability and faster time-to-market.
Key Industries and Applications
Here are the key sectors where rigid-flex PCBs are in high demand:
- Aerospace and Defense: Our rigid-flex PCBs are trusted in the aerospace and defense sectors for applications such as satellite systems, avionics, and military communications. Designed to withstand extreme temperatures, vibration, and mechanical stress, our boards are ideal for harsh environments. We provide solutions for space-constrained systems like antennas and radar, ensuring high performance and long-term reliability even in challenging conditions.
- Medical Devices: We provide rigid-flex PCBs for medical devices requiring miniaturization, durability, and precision. Our boards are perfect for implantable devices, diagnostic equipment, and wearable health monitors. The flexibility of our designs allows them to fit seamlessly into compact medical devices, while maintaining the reliability needed for critical health applications.
- Consumer Electronics: Our rigid-flex PCBs are commonly used in portable electronics such as smartphones, tablets, wearables, and laptops. The compact and lightweight nature of our designs makes them ideal for space-sensitive consumer electronics. Our solutions combine high-density interconnects with flexible features to reduce size and weight without compromising on performance.
- Automotive Electronics: In the automotive industry, our rigid-flex PCBs are integrated into advanced driver assistance systems (ADAS), electric vehicle (EV) components, and infotainment systems. Our designs endure the demanding conditions of automotive environments, including temperature extremes, vibration, and mechanical stress, ensuring reliable and efficient performance throughout the vehicle’s lifetime.
- Industrial Automation: Our rigid-flex PCBs are used in industrial automation applications, such as robotics and control systems. The durability and space-saving advantages of our designs make them ideal for rugged equipment in factories and warehouses. By reducing weight and size while enhancing performance, our PCBs contribute to the efficiency and reliability of industrial automation systems.
- Telecommunications: We provide rigid-flex PCBs for telecom infrastructure, including network equipment like base stations, routers, and data servers. Our designs help optimize space and weight while maintaining high-performance standards.
Why Choose HT Global Circuits for Rigid-Flex PCBs?
Here are some reasons to choose HT Global for your rigid-flex PCB needs:
- Material Expertise: We prioritize optimal material selection by rigorously testing dielectric properties across various temperature, humidity, and frequency ranges. Our partnerships with top substrate manufacturers keep us at the forefront of material advancements, ensuring the highest quality rigid-flex PCBs for your needs.
- Precision in Layer Alignment and Registration: We prioritize accuracy in layer alignment using high-precision equipment, guaranteeing tight tolerances to ensure signal integrity and meet performance standards, even in complex multi-layer designs.
- Structural Integrity and Durability: Our rigid-flex PCBs are built for durability with stiffeners and coverlays that ensure flexibility and resistance to mechanical stress, while maintaining thermal stability and long-term reliability in extreme conditions.
- Advanced Manufacturing Capabilities: Leveraging cutting-edge technology, we maintain precise tolerances and strict quality control at every stage of production, from prototyping to full-scale manufacturing, ensuring each PCB meets and exceeds industry standards.
- Custom Design Support: We work closely with engineers to support custom designs, providing expertise in stack up development, signal integrity, and DFM analysis to optimize production, minimize rework, and accelerate time-to-market.
- Reliability Testing and Quality Assurance: Our rigorous testing ensures each PCB meets mechanical, electrical, and thermal performance standards, guaranteeing reliability under demanding conditions.
Get your PCBs Built – Fast
HT Global Circuits delivers quick-turn, high-quality PCBs with transparent pricing and reliable delivery. Order now to keep your projects on track.
Frequently Asked Questions
The lifespan of these boards depends on factors like the operating environment, thermal cycles, and mechanical stress. However, with proper design and usage, they can last for many years, often exceeding 10+ years in demanding applications such as aerospace and medical devices.
- ISO 9001: Quality management systems.
- ISO 14001: Environmental management systems.
- IATF 16949: Automotive quality management systems.
- AS9100: Aerospace quality management systems.
- UL Certification: For safety and performance standards.
Rigid-flex PCBs are generally more expensive than traditional PCBs due to the complexity of their design and the additional manufacturing processes required. However, they offer significant cost savings in the long term by reducing the need for connectors, interconnects, and the overall size of the assembly, which can lower assembly and maintenance costs.
Yes, rigid-flex PCBs are suitable for both prototyping and mass production. While the initial prototyping stage requires close attention to design and testing, once the design is finalized, rigid-flex PCBs can be produced at scale with high reliability and cost-effectiveness. The advanced manufacturing techniques employed ensure that both small and large volumes meet the same quality standards.
While rigid-flex PCBs are robust and designed for high reliability, they can be challenging to repair or rework, especially in the flexible areas. Repair is generally possible but may require specialized techniques and equipment. It’s crucial to ensure proper design and manufacturing to minimize the need for repairs.
The lead time for manufacturing rigid-flex PCBs can vary depending on the complexity of the design, material selection, and production volume. For prototypes, the lead time is typically 2-4 weeks, while larger production runs may take 6-8 weeks or more. Lead times can also be affected by any specialized testing or certifications required.