We now have the power to make electronic units smaller than ever before, but like everything in product design, the profitable engineer must contemplate all of the trade-offs. Due to the upper quantity of setup required by the manufacturer, flexible PCBs are dearer to prototype with than rigid boards. For extra complex designs, I recommend producing mock-up rigid PCBs first to test out all of the electronics before ordering flexible PCBs. Provided that the timeline permits it, designing and building inflexible mock-ups first can save costly flex re-spins down the road. Flexible PCBs are all the rage now, and for good purpose.

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From moveable pop-up shows to giant custom-built exhibits, we have solutions for companies of all sizes and industries. The copper traces on flex PCBs are susceptible to cracking and tearing. This may be avoided by including correct design options corresponding to tear stops and teardropped holes, and by following the IPC recommendations for minimum bend radius. Also, although the board is flexible, the parts most actually aren’t. This could cause solder joint cracking except the sections with elements are stiffened. Stiffening is usually achieved with an FR-4 sheet glued to the other aspect of the board.

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Shrinking a inflexible PCB through the use of smaller elements with higher densities can only go so far. Flex PCBs are, as the name implies, circuit boards made out of flexible supplies. Using a flex board allows the designer to contour the electronics to any out there house inside the gadget, permitting tight integration between the mechanical and electrical design. Flex boards have more advantages than simply providing more surface area for PCB elements. Flexible PCBs can replace interconnects usually fashioned by connectors and wiring harnesses in typical designs.

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