Flex Circuit Manufacturers
A flex circuit manufacturer is one that offers a product to produce flexible printed circuit boards. Unlike standard PCBs, which have a fiberglass or metal base, flex circuits use a flexible polymer core. The majority of flex circuits utilize a polyimide (PI) film as their base. This material does not soften when heated, so it retains its flexibility after thermosetting. PI is also less susceptible to humidity and tears, which makes it the ideal choice for flexible circuit construction.
The core is then clad with rolled copper. This is a much thinner copper foil than that used in rigid PCBs. It is bonded to the PI using Bondply, which isolates the conductive layers similar to prepreg found on rigid PCBs. This material is available in several different versions and thicknesses, allowing the flex circuit to be made with either double-access or single access conductor patterns. Double-access flex has the added benefit of being able to be accessed from both sides, which allows easier reworking if errors occur during manufacturing.
Conductor patterns are then etched onto the PI using photoresist film, which is laid on top of the panels before being exposed to UV light. The result is a pattern on the PI that is readable to the machine. This step is crucial to the successful manufacture of a flex circuit. Once the etching process is complete, the panels are ready for assembly and solder masking. The solder masking ensures that the areas of the flex circuit that will not be connected to components are masked off, which prevents them from being exposed to heat during production and damage when assembled into a finished product.
Flex Circuit Manufacturers – What Is It?
While the flex circuit is being manufactured, it can undergo a variety of additional processes. For example, a flex circuit can be laminated with another layer of PI to create a multi-layer board. This is useful in a number of applications where the flex circuit manufacturer will be subject to extreme conditions, including exposure to chemicals and radiation. A flex circuit can also be combined with rigid sections to form rigid-flex circuits, which are useful in products that need to be both flexable and durable.
Lastly, a flex circuit can be slit into strips for easy insertion into an assembled product. This can be particularly useful for applications that require a large amount of wiring and are designed to bend during normal operation. This technology replaces wire harnesses that are heavy and bulky, which can add weight and limit a product’s range of motion.
Flex circuits offer design flexibility, reduced wiring considerations and cost savings compared to traditional hand wiring and rigid circuit boards. Moreover, a flex circuit can be more reliable over time than a traditional PCB. It can also withstand more dynamic forces than other types of PCBs, and it is ideal for uses in which the product will be bent or twisted during operation. This makes them a popular choice for medical and surgical devices, laptop computers, mobile phones, handheld electronics, and consumer products.