Rigid-Flex PCB: Everything You Need to Know

Geospace Technologies Contract & Manufacturing Division

February 10, 2023

Australian engineer Paul Eisler invented the first printed circuit board (PCB) in 1936. Since then, board technologies have evolved; now, PCBs are in almost every device humans use.

But there are many kinds of PCBs to choose from when making tech. Selecting the most suitable one comes down to understanding its applications and benefits.

A rigid-flex PCB, for example, has many capabilities that other PCBs do not. It’s among the most popular types of PCB available. Read on to learn about rigid-flex PCBs, their applications, benefits, and assembly processes.

What Is Rigid Flex PCB?

PCBs are an essential part of any electronic product. PCBs work as a bridge to connect components and circuits.

Copper layers bonded to a non-conductive substrate comprise PCBs. These tiny circuits provide mechanical support for all the components on the board.

In general, PCBs come in two different forms: rigid and flexible. Rigid PCBs are inflexible, offering a high level of durability but limited give. On the other hand, flex PCBs are more pliable boards that can bend and twist but offer less durability than rigid boards.

Rigid-flex PCBs combine the best of both worlds. They offer a combination of rigid and flexible materials in one circuit board. This allows the circuit board to bend and twist in certain areas while staying fixed like rigid PCBs.

Manufacturing rigid-flex PCBs requires a more complicated process than other PCBs. Rigid-flex PCBs experience many lamination and bonding stages to achieve their ideal balance. Though it takes more time to produce, rigid-flex PCBs’ benefits are worth it.

Benefits of Using Rigid Flex PCB

Compared to other PCBs, rigid-flex makes a difference in design freedom and durability. The benefits of the rigid-flex options include the following:

Freedom of Design and Innovation

Other PCB options limit the design process. Engineers must change their designs based on the PCB’s pitfalls. For example, a rigid PCB may be necessary for a durable product, but it can’t fit nicely into a smaller space.

On the other hand, a flex PCB might be perfect for a tiny electronic, but it doesn’t offer much-needed durability. Rigid-flex PCBs solve this problem.

Rigid-flex PCBs are durable and can flex into tight positions. So, engineers have unlimited freedom of design and innovation when using them.

Space Saving

Rigid-flex PCBs have the unique capability of bending to 3-D shapes. They also excise the need for connector cables between rigid circuits. These crucial benefits result in space and weight-saving circuits.

Efficient Assembly

Rigid-flex PCBs are so flexible that assemblers can bend them. Rigid circuit boards would require one to solder individual pieces together. But, each solder joint creates a weak space on the PCB.

By printing a whole rigid-flex PCB and bending it into shape, solder joints are a thing of the past. That makes rigid flex PCBs more durable. So, they stand up to warping and usage in harsh environments.

Cost Reduction

The cost of using rigid-flex PCBs is much lower than traditional circuit boards. This is due to the increased efficiency of the manufacturing process. This cost reduction is most beneficial in large-scale manufacturing applications.

Complex Design Capabilities

By utilizing board technologies like rigid-flex, engineers can achieve more complex designs. The result is innovations that wouldn’t be possible with flex or rigid PCBs. Rigid-flex allows for smaller, more streamlined, and more reliable technology.

Improved Heat Dissipation

Rigid-flex PCBs also provide improved heat dissipation, leading to less overheating. This is a huge benefit, as it allows for greater longevity and stability of the components. That means you can increase the load on the PCB without worrying about overheating or total system failure.

Applications and Industries

Rigid-flex PCBs provide reliable circuit support to tech for various applications. These include the following:

Smart Technology
Cell Phones
Cameras
Computers
Aerospace Systems
Automotive Systems
Medical Devices
Military Weapons
Military Weapon Control Systems

Rigid-flex PCBs provide a reliable and efficient way to connect electronic components for these applications. Therefore, critical industries like the military and medical rely on rigid-flex PCBs to power their tech.

However, commercial manufacturers of smart devices and computers still find rigid flex preferable. When they use these types of PCBs, they create a more reliable product. So, more consumers want to buy big-ticket items from them.

Rigid Flex PCB Design Process

Designing rigid-flex PCBs can be a complex process, but with the right approach and tools, it doesn’t have to be. You should begin with an understanding of your project’s goals.

Working with engineers or PCB manufacturing designers will help you design your vision.

From there, you’ll need to choose the best PCB materials for your design. You can also decide whether the material has halogen and the material’s thermal, chemical, mechanical, and electrical properties.

Once the design is complete, you’re ready to begin manufacturing. But manufacturing is only one part of the process. After that, you’ll need to assemble your PCBs.

Rigid Flex PCB Assembly Process

Assembling rigid-flex PCBs requires specialized circuit board assembly technologies and processes. Unlike traditional PCBs, rigid-flex PCBs have many layers of rigid and flexible circuits. So, the assembly process for rigid-flex PCBs is more complex.

The first step in the manufacturing process is to create the rigid-flex PCB stack-up. This involves laying down the flexible and rigid layers in their proper order.

Then, an assembler adds the components to a pick-and-place machine. This machine can identify and arrange both rigid and flexible components.

After placement, the components get laminated together. Then, assemblers remove excess materials from the rigid-flex board.

Finally, the assembler performs post-processes, such as applying finishes, soldering, and drilling. Once that’s finished, the rigid flex PCB is ready to package and ship.

PCB Assembly With Geospace Technologies

Selecting a rigid flex PCB over traditional PCBs is simple. However, choosing a PCB assembly manufacturer can be challenging. If you need a reliable service provider at the top of the game, look no further than Geospace Technologies.

With years of experience and innovative board technologies, we are well-equipped to handle customer needs. Whether a simple design or a complex engineering project, Geospace Technologies has you covered.