Flex PCB Manufacturer Assist Customers
When creating a flexible printed circuit board, it is important to follow the same rules as when designing a rigid PCB. This will ensure that the product works as intended and has adequate performance. It is also essential to make sure that the design follows the IPC standards, as these will dictate how the product must be constructed and what materials are used.
The first step is to create the CAD file, using a PCB design software program. This will provide the foundation for the flex pcb manufacturer design and layout, including the traces, pads, and pins. Once the CAD file is completed, it is sent to the manufacturer for fabrication.
During the fabrication process, the copper layers are patterned on the FR4 or Rogers 4003 substrate material using photoresist coated panels and a stencil with the desired mask pattern. Then the copper is chemically etched and the holes are drilled, which allows the components to be attached to the board. The copper is then plated with copper in the same way that is done for rigid PCBs. Finally, the board is coated with a solder mask to protect the copper from corrosion and short circuits.
How Does a Flex PCB Manufacturer Assist Customers?
Since a flex PCB is more prone to bending, it requires a different design that can support expansion and contraction for longer periods of time without breaking. The traces should be routed with consideration to the expected bending angle, and the designers should use curved traces rather than straight ones to reduce stress that thins the copper. Additionally, if the PCB is to be bent multiple times, it may be necessary to stagger the traces to avoid stress points.
A flex PCB also needs stiffeners that are laminated on certain areas of the board to give it additional structural strength. These are a good idea for areas such as edge connectors and mounting holes. A flex PCB with stiffeners will also have a greater tear resistance than a rigid one.
In addition, the flex PCB will need to be tested to ensure it is functioning properly and that it is up to IPC standards. The tests can include things such as flex cycles and dynamic bending. The test results will help the flex PCB manufacturer to identify potential problems and make adjustments if necessary.
A flex PCB is an excellent option for a wide variety of applications. It can be designed to replace rigid PCBs in assemblies and is a more cost effective solution for smaller jobs. However, it is important to partner with a capable flex PCB manufacturer able to handle the complexity, quality requirements, and volumes of each job. When selecting a flex PCB manufacturer, it is recommended to look for one that offers a quality guarantee and certifications that show their commitment to providing a high-quality product. It is also helpful to find a flex PCB manufacturer that can provide a fast turnaround on quoting and inquiries.