lexible circuit boards more expensive
When designing your new electronic device, it’s important to take the full picture into account. This includes all costs from design to fabrication, and even shipping and assembly. Using a rigid-flex PCB can eliminate the need for multiple wire assemblies and connectors in your product, resulting in lower costs over the life of the product. However, many customers wonder whether flex or rigid-flex circuit boards are more expensive than their rigid counterparts.
A Printed Circuit Board (PCB) is the heart of an electronic device, connecting all of the components together. Rigid PCBs are typically made with FR-4 laminated fiberglass, which is the cheapest material available for the construction of circuit boards. Flexible and rigid-flex PCBs are constructed with more expensive materials, including polyimide and other advanced materials. This gives them the ability to bend and flex, as well as tolerate harsh operating conditions.
The cost of a flexible circuit board depends on several factors, including the number of layers and the size of the board. Increasing the number of layers can increase the cost, and it is recommended to keep layer count to a minimum for the best price/performance. A high number of layers is more difficult to fabricate, and it increases the complexity of the lamination process. It also requires a higher amount of copper, which can significantly increase the price.
Are flexible circuit boards more expensive than rigid ones?
Other factors include the number and size of holes, which can also significantly impact the price. Smaller holes are more difficult to drill, which increases the overall fabrication time and adds to the cost. In addition, if the PCB requires unique specifications such as solder mask clearance or side plating, these can add to the overall cost as well.
A final factor is the type of manufacturing process. Using a leaded process is usually cheaper than a through-hole process. Similarly, using an IPC-2610 cleaning process is more cost-effective than ionic contamination and flying probe testing. Another significant consideration is the number of designs. Creating multiple rigid PCB and cable designs can result in higher design and engineering costs. When moving to a rigid-flex solution, the designs can be merged into one design and part number, which helps to reduce development and management costs.
Ultimately, the decision to use a flex or rigid-flex circuit should be driven by the need for design flexibility, ease of fabrication, and performance in harsh operating environments. While flex and rigid-flex circuits are more expensive than their rigid counterparts, they can save you time and money over the life of the product by eliminating the need for multiple wire assemblies and connectors.
Rigid-flex and flex PCBs are much more versatile than their rigid counterparts, providing more design options while reducing component and assembly costs. This allows for a more compact and resourceful electronic device that can operate in any environment. While the initial cost of a rigid-flex or flex circuit board may be more expensive, recouping this additional expense can be achieved in production volumes of 2000 pieces or less.
