Rigid Flex Circuit Boards and Their Applications

Rigid flex circuit boards offer the best of both worlds, combining rigid PCB technology with flexible features. The result is a robust, reliable product that provides superior durability and reliability in a highly compact, lightweight design. These PCBs are particularly suited for critical applications, such as in medical and military equipment. When the failure of a single component can lead to hazardous conditions or costly downtime, it’s important to use high-quality rigid-flex circuits to avoid dangerous or catastrophic circumstances.

rigid flex circuit incorporate a combination of rigid and flexible circuit board technology to form a hybrid that is able to withstand the forces of dynamic flexing while maintaining stability and support for the circuitry. The flex portion of the circuit board can take on the shape of a flexed curve during installation (also known as flex-to-install), and it’s capable of being molded to fit into tight spaces. These PCBs can also be panelized for easy handling and assembly through the pick-and-place and wave soldering processes.

In addition to their ability to withstand bending, these multilayered circuits feature rigid areas on top of the flexible layer, allowing for better electrical performance and improved connections between rigid and flex sections. A rigid-flex circuit can also be designed with a variety of components and connections, including through holes, blind vias, buried metal layers, and more. This gives engineers the flexibility they need to design a PCB that will work for a specific application without sacrificing the integrity of the circuitry or the functionality of the device it’s being used in.

The Advantages of Rigid Flex Circuit Boards and Their Applications

Another advantage of rigid flex circuits is their enhanced resistance to shocks and vibrations, which can be a major factor in the failure of some products. These PCBs are able to withstand the type of physical stress that would normally result in part failure, and they maintain this level of durability when subjected to drop tests. Additionally, rigid flex PCBs are able to tolerate environmental factors such as UV light, chemicals, oils, and radiation exposure.

While the flexibility and durability of rigid flex circuits can provide significant advantages, the complexity they add to the production process can require an increase in engineering resources. However, using a comprehensive PCB design and manufacturing solution like Altium Designer with its integrated flex-circuit features can make it easier to create high-quality, durable rigid-flex circuits that meet or exceed industry standards.

In order to optimize flexibility in a rigid-flex PCB, it’s important to adhere to the IPC-2223 Design Guidelines. This includes routing all circuitry perpendicular to the bend, avoiding the use of plated holes or vias within 100 mils of any flex-rigid junction, and ensuring that all traces from the flex section are unbonded before the rigid section begins. Lastly, it’s vital that the adhesive on a rigid-flex circuit is thick enough to withstand the forces of bending. These best practices will help to ensure that the resulting rigid-flex PCBs are both accurate and resilient for any type of application or environment.