Light & Thin
Replacing bulky wiring, flex PCBs are incredibly thin (~0.004″). This cuts down on weight and volume compared to rigid boards or harnesses, allowing for the design of much lighter and more compact electronic devices.
8:00 - 17:30
Monday to Saturday
Monday to Saturday
HIGH-RELIABILITY FLEXIBLE PCB MANUFACTURING
With advanced facilities and expert engineering, PCBAIR delivers high-reliability flexible PCBs tailored for compact, lightweight, and dynamic applications. From single-layer to complex multilayer and rigid-flex designs, we support full customization with tight tolerances, fast lead times, and consistent quality.
Flexible Design
A key advantage is flexibility. Flex circuits bend, fold, and twist to fit uniquely shaped spaces. They wrap into tight gaps, enabling innovative designs impossible with rigid boards and letting the circuit conform to your product.
High Density
Flexibility doesn’t sacrifice performance. They support the same dense circuitry as rigid PCBs, allowing for complex interconnects on one thin film. A flex circuit offers the precision of a rigid board in just 10% of the space of cables.
High Reliability
Built for motion, flex circuits excel under constant vibration and bending. A well-designed board endures millions of flex cycles without cracking, making it ideal for robotics or wearables, with natural shock resistance for a long life.
Flexible Circuit Manufacturing for Any Application
Flexible PCBs are engineered in several key constructions to meet diverse design needs. Single-layer circuits provide simple, reliable interconnects for basic applications. Double-layer versions add copper and plated vias for higher circuit density in modern electronics like digital cameras. Multilayer flex integrates three or more layers for maximum density in advanced systems. Finally, rigid-flex PCBs combine rigid and flexible sections into one unified board, offering sturdy mounting and 3D routing to maximize reliability by eliminating connectors.
As a PCB manufacturer, we are equipped to produce all types of flexible circuits, from single-layer prototypes to the most complex multilayer and rigid-flex boards. Our advanced processes support exceptionally fine trace and spacing down to 2 mil (0.05 mm), enabling high-density routing. We work with a wide range of quality materials, including industry-standard polyimide (Kapton) and various copper weights (0.5 oz to 2 oz), allowing us to perfectly balance flexibility with your current-carrying requirements.
For dynamic applications, we utilize rolled-annealed (RA) copper, whose grain structure is ideal for repeated bending and maximum endurance. We also integrate localized FR4 or steel stiffeners for secure component mounting and selective EMI shielding to ensure signal integrity. These custom capabilities, combined with options like specialized polyimide coverlays, ensure we can build a circuit that meets virtually any mechanical or electrical specification for your project.
Manufacturing Process Challenges & PCBAIR Solutions
Producing high-quality flexible PCBs means overcoming unique fabrication hurdles. At PCBAIR, we have invested in the technology and expertise to turn these challenges into reliable manufacturing solutions.
Coverlay Alignment & Application
Aligning the protective polyimide coverlay demands extreme precision. Even a slight misalignment can block pads or expose copper traces, while trapped air bubbles can compromise insulation and reliability.
We solve this using automated systems.
- Automated Optical Alignment (AOA): This technology ensures the coverlay is positioned perfectly over the circuit pattern before bonding.
- Vacuum Lamination: By bonding the layers under controlled heat and pressure in a vacuum, we eliminate trapped air, resulting in a smooth, void-free bond that fully protects your circuitry.
- CCD-Guided Laser Cutting: For creating openings (“windows”) for component pads, we use laser systems guided by CCD cameras. This achieves exceptional accuracy, preventing off-center or misshapen openings.
Fine-Line Etching & Control
The thin, flexible materials used in FPCs are susceptible to damage and over-etching, which can ruin high-density designs.
Our facility is equipped with specialized processing lines designed to handle fragile materials with care.
- Precision Etching Lines: This equipment provides constant support for thin cores, ensuring consistent trace widths and minimizing defects.
- Advanced Imaging: We use high-resolution lithography and Laser Direct Imaging (LDI) for our most demanding projects. This ensures that the final circuit precisely matches your original design, even with very fine features.
Adhesion & Layer Bonding Integrity
In multilayer or adhesive-based flex circuits, high temperatures can cause adhesives to soften, leading to delamination or cracked vias. Pads in flexing areas are also at risk of lifting.
We build reliability into every layer through superior materials and proactive design.
- Adhesiveless Laminates: Whenever possible, we use base materials where copper is bonded directly to polyimide. This enhances thermal performance and eliminates the risks associated with adhesives.
- High-Performance Adhesives: When an adhesive is necessary for bonding stiffeners or layers, we select high-grade flexible adhesives and use tightly controlled curing cycles.
- Design for Reliability: Our engineers incorporate features like anchor pads and tear stops to mitigate stress points. Every multilayer design also undergoes a thorough DFM review to prevent issues before fabrication begins.
Long-Term Bending Durability
The primary goal of a flex circuit is to bend reliably without failure. This requires a combination of smart design choices and specific manufacturing processes.
We partner with you to build boards that last, verifying their strength through real-world testing.
- Superior Materials: We recommend and use RA copper for dynamic applications. Its unique grain structure dramatically improves flex life, allowing for hundreds of thousands of bend cycles.
- In-House Bend Testing: We don’t just assume reliability; we prove it. We perform rigorous in-house bend testing on sample units to verify that they meet or exceed your required cycle life.
Why Choose Us as Your Flexible PCB Manufacturing Partner?
We accelerate your project from concept to market. Get prototypes in as fast as 48 hours and transition seamlessly from initial designs to high-volume production. Our end-to-end in-house process ensures rigorous quality control at every step. To prevent costly errors and optimize your design, our expert engineers conduct a complimentary DFM review before fabrication begins. With the capability to meet the most stringent IPC Class 3 standards, our boards deliver a proven formula of high reliability, competitive cost, and responsive technical support. This combination makes us your trusted partner for your project’s success.
Competitive Pricing
With over 10 years in the PCB industry, PCBAIR has established a reliable supply chain that ensures access to premium components at competitive prices. For complex projects needing special materials or advanced technical specifications, our strong manufacturing capabilities enable us to provide cost-effective solutions while maintaining high quality.
Fast and Reliable Delivery
We ensure rapid production times, with samples shipped within 24-48 hours and mass production orders delivered within 72-120 hours. Our partnerships with global logistics providers like UPS, EMS, FedEx, DHL, and TNT guarantee prompt and reliable shipping, supported by our digitalized factory management and 90% automation for enhanced efficiency.
Quality Assurance
Our rigorous quality inspection begins with incoming material checks. We use AOI to detect defects and X-ray to identify internal issues. Electrical performance testing is performed with advanced automatic test machines and flying probe testers. Before shipment, our dedicated QC team conducts a thorough manual visual inspection to ensure all products meet strict quality standards.
Customer Service
Our experienced sales, order management, and engineering teams provide expert support throughout your project. The sales team handles support and project follow-ups, while the order management team ensures timely quotations and monitors production status. Our engineering team reviews your design files, offering professional advice to optimize production efficiency.
PCB Laminate Materials Suppliers
To ensure your PCBs are reliable and perform well, we use high-quality laminate materials. We have built strong partnerships with top suppliers in the industry, including trusted brands like Rogers, Panasonic, Dupont, Arlon, Taconic, Nelco, Isola, Teflon, and more. This means you receive the best materials tailored to your project needs, providing the performance and durability you expect.
Flexible & Rigid-Flex PCB Capabilities
By reviewing the following flexible PCB capabilities table, you can briefly understand what we can do.
| Specification | Capability |
|---|---|
| Construction Type | Single-Sided, Double-Sided, Multi-layer FPC & Rigid-Flex PCB |
| Base Material (Dielectric) | Polyimide (PI), Polyester (PET) – Adhesive & Adhesiveless Constructions |
| Layer Count | Flexible: 1-12 Layers; Rigid-Flex: 2-24 Layers |
| Overall FPC Thickness | 0.05mm – 0.4mm (excluding stiffeners) |
| Base Copper Thickness | ⅓ OZ, ½ OZ, 1 OZ, 2 OZ (12µm, 18µm, 35µm, 70µm) |
| Minimum Trace / Space | 2/2 mil (0.05mm / 0.05mm) |
| Minimum Drill Size | Mechanical: 0.15mm; Laser (Microvia): 0.075mm |
| Minimum Bend Radius | Dynamic Flex: 6x FPC thickness; Static (Bend-to-install): 1x FPC thickness |
| Stiffener Material | Polyimide (PI), FR4, Stainless Steel, Aluminum |
| Stiffener Thickness | 0.1mm – 2.0mm |
| Finished Surface | ENIG (most common), Immersion Silver/Tin, OSP, Hard/Plated Gold (for fingers) |
| Coverlay / Flexible Solder Mask | Amber (Yellow), White, Black |
| Impedance Control | ±10% standard, up to ±5% on request |
| Special Process | EMI Shielding (Silver ink / Copper mesh), Gold Fingers, ZIF connector support |
Need Help With Your Project?
Please send us a message, and our flexible PCB manufacturing capabilities can help you complete your next project.
Flexible PCB Samples We Manufacture for Our Customers
To guarantee quality, we employ rigorous testing throughout fabrication. AOI verifies circuit integrity after key steps, followed by 100% electrical testing on all boards to confirm connectivity. For flex-specific demands, we perform critical bend cycle tests for durability and use TDR to validate controlled impedance on high-speed designs. A final, meticulous inspection against IPC standards ensures every circuit we ship is reliable and built to perform.
Flexible PCB Manufacturing Equipment
Our 65,000 sqft production campus is equipped with advanced fabrication machinery. High-precision UV lasers cut intricate outlines and drill microvias with micron-level accuracy. Automated lamination machines then bond coverlays under vacuum pressure for a perfectly registered, bubble-free finish. Our precision etching lines, optimized for delicate flex materials, provide tight control over trace widths, enabling the creation of complex, high-density circuit designs.
This precision is then verified by our advanced quality control technology. AOI systems scan boards after key stages to catch any defects early. We utilize flying probe testers for fixtureless electrical testing on every circuit, which is ideal for prototypes and complex layouts. Finally, our custom in-house test rigs validate mechanical durability, performing bend cycle and stress tests to ensure our flex PCBs will perform reliably in your specific application.
