Are Rigid Flex Circuits More Expensive
Rigid flex circuits can be more expensive to make than traditional PCBs. However, their unique capabilities and design versatility often make them an ideal choice for a wide range of applications. They can also help reduce assembly costs by eliminating the need for extra connectors and cables. This can be especially helpful when it comes to a product’s design, where space and weight reduction are key.
Rigid-flex PCBs are an excellent option for a wide variety of applications, from consumer electronics to medical devices and aerospace equipment. Their ability to bend and flex provides a flexible layout that can help manufacturers create sleeker designs with increased functionality. This flexibility also allows for improved ergonomics, which can improve user comfort and increase the lifespan of a device.
One of the main drivers of cost for a rigid flex circuits is its copper clad laminates. These are typically made from a base film, such as PET (Polyethylene terephthalate), PEN (Polyethylene naphthalate) or polyimide. Some are designed with an adhesive system to bond the copper onto the base films, while others are not. Adhesive-less laminates generally have lower cost than other types of rigid flex boards, but they don’t offer as much mechanical support. Thicker, more durable base films, such as polyimide or fluoropolymers, are also available but will come at an additional cost.
Are Rigid Flex Circuits More Expensive Than Traditional PCBs?
Another component of the cost for a rigid flex is its through-hole plating. This is done using a similar process to conventional hard board manufacturing, where copper is deposited and chemically etched into the pads or vias. The difference is that a rigid flex will have at least 1 mil of copper composite, whereas conventional copper has 1/2 mil. In addition, a rigid flex will need a photosensitive mask pattern to expose and develop the resist prior to the copper deposition.
While these factors can drive up the cost of a rigid-flex PCB, they aren’t necessarily permanent. A good fabricator will work with designers to make sure their rigid-flex circuits are designed for manufacturability, and this can help minimize costs in the long run.
Rigid flex PCBs can also be more affordable than rigid PCBs when they are being used for prototypes and low-volume production runs. This is because the NRE (non-recurring engineering) costs associated with design setup are amortized over a larger production run, which reduces the unit price per rigid-flex board.
A final factor to consider when comparing the cost of rigid flex versus traditional PCBs is the amount of material required. Some components, such as core laminate, prepreg, copper foil, and cover layers, are the same for both types of PCBs. Other materials, such as solder mask and silkscreen, can be more costly for rigid flex.
Ultimately, the decision to use rigid flex or traditional PCBs will depend on several different factors, including the application’s requirements and budget. A rigid-flex circuit is an excellent solution for a wide range of applications, and its unique capability to fold and bend can reduce assembly costs in the long run by eliminating the need for connectors and cables.