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The process of working with a flex PCB manufacturer is different from standard circuit boards. They require special processes for forming the layers, bonding, and finishing of the product. The main difference is in the material used to create the flexible dielectric substrate and the copper circuits that are spread over it. The most common material is polyimide (PI), but it is also possible to use thermoplastic materials like PET or PBT, as well as liquid crystal polymer (LCP).
There are a few different things you need to consider before choosing a flex pcb manufacturer. The first is the layer count. You need to know if you will need a single- or double-sided flex circuit, or a multi-layered design. Other considerations include the material choice, the current rating and whether your design requires shielding or stiffeners.
Another thing to look at is the thickness options for your flex circuit. Typically, the thinner a flex circuit is, the better it will perform. This is because the smaller space between traces will result in lower impedance and improved signal flow.
The Process of Working With a Flex PCB Manufacturer
Once you have your design and the materials are chosen, the next step is to create a master panel of flex circuits. This will allow you to test your prototype and make sure it works before moving on to full production.
Before lamination, the individual flex layers are cleaned using isopropyl alcohol to remove any contaminates from the surface. The layers are then stacked together and secured using an adhesive. These adhesives are commonly called PSAs and are applied by removing a liner and pressing the material to the PCB.
After the adhesive is applied, a thin coating of copper is added to each area of the circuit. This layer is then bonded to the adhesive with heat and pressure. The copper coating provides electrical conductivity to the circuit.
The finished flex circuit is then cut to the proper size and shape using a laser. This is done with extreme accuracy and precision. A laser is also capable of cutting very fine lines in the PCB, allowing for tighter spaces between pads and traces.
Once the flex circuit is finished, it is then ready to be shipped out for assembly. Typically, this is done in batches and can be delivered within a few days. This is especially helpful for customers who need quick turnaround times and need to be able to work with short lead times.
Flexible circuits are becoming more and more popular for many applications. The main advantages of these are their dynamic flexibility to bend and fold, lightweight and compact construction, ability to take custom 2D shapes, increased ruggedness against vibrations, simplified assemblies by eliminating connectors, and potential longer-term cost savings. They are most often found in medical equipment, consumer electronics, robots and industrial machines, automotive equipment, and aerospace avionics. However, they are a great solution for many other industries too.
