How Are Rigid Flex Rigid PCBs Manufactured?
Rigid Flex Rigid PCBs Manufactured
Rigid flex rigid pcbs combine the best of both worlds, combining the durability of rigid boards with the flexibility and space efficiency of flexible circuitry. They are ideal for a wide range of electronics applications, such as bending areas in mobile phones or laptops, screen signal connections and many other applications that need to be able to withstand some degree of physical stress. In addition, they offer increased thermal stability, which allows them to withstand high levels of vibration and shock, making them a superior choice for applications in harsh environments like military, aerospace and automotive equipment.
Unlike traditional rigid PCBs, a rigid flex can withstand high temperatures and extreme environmental conditions, allowing it to be used in a wider range of applications than other types of printed circuit boards. This is due to its hybrid design, which combines the rigid base of a conventional rigid board with a flexible dielectric film that can be bent or folded. The flexibility of the flex allows it to fit into tight spaces and bendable areas, which can save space in electronic devices and enable them to be more compact and more sophisticated.
A specialized contract manufacturer that specializes in rigid flex rigid pcb fabrication can work with you to ensure your design meets the specific requirements of your application, and that the finished product will perform as expected. Rigid flex PCBs require more complex fabrication techniques than other types of PCBs and can be difficult to manufacture in low-volume production runs, so it is important to find a manufacturer that has the right expertise and experience to deliver a quality result.
How Are Rigid Flex Rigid PCBs Manufactured?
Before production can begin, a Gerber file is required, which contains the layout and layer sequence of each part of the board. The layout must be carefully planned to ensure that the rigid flex circuitry is positioned properly and will not interfere with the rigid layers. The Gerber file must also include the necessary materials to meet your project’s requirements, including UL flammability rating, mechanical considerations and impedance control for both the rigid and flexible circuitry.
Once the flex circuitry is positioned correctly on the rigid PCB, the copper foil is etched through the entire stackup. After this, holes with the required specifications are drilled, deposited with copper and chemically plated to provide layer-to-layer electrical interconnection. This step must be carried out with the utmost precision and care to avoid damaging the flex circuitry. Finally, the flex and rigid sections of the board are covered with an adhesive-free or photo-imageable solder mask.
The coverlay is then cut to shape, and any components mounted on the flex are soldered to the corresponding pads on the rigid PCB. The final PCB is then inspected and tested for quality. Rigid flex PCBs can have a higher component density than rigid PCBs, allowing them to accommodate more features in a smaller space and reducing the number of connectors needed. This can make them a cost-effective solution for high-density applications.