PCB Flex Rigid Prototyping
PCB flex rigid prototyping is used in many applications where both flexibility and structural integrity are needed. Rigid-flex circuits are often found in industrial applications, automotive and aerospace vehicles, medical devices, wearable technology, and consumer electronics. However, they are not without their challenges. Proper design and quality control are essential to ensuring that these multi-layered devices perform as intended. To meet these demands, proper design is essential, and careful consideration of material selection, thermal management, layout, and design for manufacturing (DFM) can ensure that the rigid-flex circuit meets all requirements.
The best way to achieve high-quality rigid flex boards is to work with an experienced electronic contract manufacturer. An ECM can provide you with the DFM services and fabrication expertise required for a successful project. In addition, working with an ECM early in the process can help you avoid any surprises during production.
One of the most important things to do when designing a rigid-flex PCB is to clearly define the flex and rigid sections. This can help to prevent stress points where the flex and rigid sections meet. In addition, the design should be clear regarding the maximum bending radius and any other tolerances that are applicable to the flex section.
Best Practices for PCB Flex Rigid Prototyping
When designing a pcb flex rigid, it is important to use narrower traces and spread them out across a flexible area in order to decrease areas of high stress. It is also a good idea to incorporate dummy traces or redundancies to increase the mechanical strength of a flexible area. It is also a good idea to avoid using solid copper in the areas that are expected to be bended frequently. Instead, hatched polygons should be used as they can maintain their flexibility better than solid copper.
Another way to increase the mechanical strength of a flex circuit is to use rounded corners. Rounding off sharp 45 or 90 degree corners can greatly increase the resistance of a rigid-flex circuit to tear failure. Finally, it is a good idea to use a filet tool on the traces in the areas that are expected to be flexed frequently. This will increase the flexibility of these traces by decreasing the amount of metal that is exposed and can also help reduce strain on the connections.
To avoid any issues during the production phase, it is a good idea to place vias in fixed areas of the board when designing a rigid-flex PCB. This will help to avoid the occurrence of cracks and fatigue in the copper during frequent bending. Additionally, the use of teardrops in the via areas can also increase the durability of the connections.
The use of a rigid-flex PCB can be an effective solution for challenging designs. But, as with any type of PCB, it is necessary to follow some key design guidelines and best practices for achieving the highest-quality rigid-flex boards. By following these tips, designers can produce robust and reliable rigid-flex circuits that will last for a long time and perform as expected.