primary advantages of using flex circuits
Rigid circuit boards have long been a key part of electronics development and production. However, in certain contexts where they simply aren’t able to meet your design and packaging requirements, you may want to consider using flex circuits instead. Flex PCBs are a specialized type of printed circuit board with extremely thin substrates, high levels of bendability and tensile strength and the ability to be molded into three-dimensional shapes to serve a wide variety of applications. They can also replace traditional wiring harnesses and ribbon connectors in many cases.
Typically made of polyester or polyimide, a flexible circuit board is constructed with conductors etched on one side of the layer and insulators on the other. Then, a coverlay is applied to protect the layers from moisture and other contaminants. A flex circuit can have any number of layers and is available in both dynamic and static versions. The conductive material is usually copper, but if the application calls for it, aluminum or silver inks can be used instead.
Dynamic flex circuit can be bent during operation while Static flex circuits are only subject to bending when being installed or removed from the product. This means that a flex circuit can be shaped to fit where a rigid board simply cannot. This opens up a wide range of new possibilities for portable, wearable and other smaller electronic devices where space is at a premium.
What are the primary advantages of using flex circuits
Flex circuits also provide a lot more flexibility in terms of the layout of components and interconnections. The fact that they are able to be bent means that you can position components in locations that would normally be impossible with rigid boards or wired harnesses. They also offer better heat dissipation than rigid boards, reducing the risk of thermal issues or other electrical problems.
In terms of assembly, flex circuits are often easier to assemble than rigid boards and wired harnesses. They have lower counts of interconnections and components, making them less likely to suffer from assembly errors. Additionally, their standardized construction process eliminates the potential for human error that can occur with traditional hand-built wiring harnesses.
As an added benefit, a flexible circuit can be reshaped to accommodate different environmental conditions. For example, a flex circuit can be bent to conform to a tight curve that would be difficult for a rigid board to manage. This can save on manufacturing costs and simplify the overall installation of the product in the field.
Another primary advantage of a flex circuit is its ability to significantly reduce mechanical space and device weight. This is particularly important in consumer and industrial products where space and weight are a critical consideration. Depending on the structure and components, customers can see up to 75% reduction in both mechanical space and device weight by switching to a flex PCB.
While there are cheaper alternatives to a high-quality, multi-layer rigid flex or a dynamic flex circuit, these solutions can often lead to thermal issues, electrical performance issues and reduced reliability in the final application. When you work with a trusted flex circuit manufacturer, you can get the best value in your investment for your product.
