Flexible circuits, also known as flex PCBs, are transforming the way we develop and manufacture electronics. Unlike regular circuit boards, these boards can bend, twist, and fit into spaces that standard circuit boards cannot accommodate. If you are wondering why new gadgets are becoming smaller, lighter, and more reliable, flex circuits are a significant contributor to this trend.
In this blog, we will talk about what makes flex circuits special, their uses, and the reasons why more engineers and companies are opting for them. We will also examine how flex PCB suppliers and circuit board suppliers in the UK are contributing to the feasibility of these designs, as well as the importance of selecting the right partners for these companies.
What Is a Flex Circuit?
Flexible circuits, also known as flex circuits, are bendable, thin boards that connect electronic parts. Unlike a regular circuit board, which is stiff, a flex circuit can bend and fold without breaking. This enables them to fit in small spaces and for components with moving parts.
Flex circuits utilise specific types of plastic film and thin copper, which enable them to be lightweight, strong, and capable of withstanding heat and vibration more effectively than rigid boards.
Essential Uses of Flex Circuits
1. Consumer Electronics
Check out your smartphone, tablet, or laptop. A flexible PCB board is inside, connecting the various components, including buttons, screens, cameras, and batteries. Flex circuits enable slimmer and lighter devices that are packed with features.
Wearables, such as smartwatches and fitness bands, utilise flex PCBs to ensure a form-fitting, flexible design around the wrist while providing ease of motion.
Cameras: Small space flexible circuits connect moving lenses with sensors.
2. Automotive Industry
Today’s cars are equipped with a wealth of electronics. Flex circuits are incorporated in displays and even used in car lights. In comparison to traditional boards, flex circuits have better handling of vibrations, heat, and tight spaces.
Dashboards and controls: Flex PCBs connect buttons, screens, and lights.
- Sensors: Used in airbags, in seat comfort sensors, and cameras.
- Lighting: Modern car lights are slim and flexible circuits that shape to fit them.
3. Medical Devices
- Medical tools require them to be compact, lightweight, and dependable. Flex circuits are ideal for these requirements.
- Pacemakers and hearing aids: Flex circuits enable these devices to be implanted within the body and withstand movement.
- Diagnostic equipment: Found in portable monitors and imaging devices.
4. Aerospace and Satellites
- Space travellers understand that weight matters significantly in space. Fuel and space are both saved by flex circuits compared to rigid boards.
- Satellites: Flex PCBs withstand vibration and temperature fluctuations during launch and in orbit.
- Aircraft: In control panels, sensors and communication systems.
5. Industrial Equipment
In regions such as factories, machines can vibrate, move, and generate excessive heat. That allows the use of flex circuits in robots, sensors, and control panels.
Advantages of Flexible Printed Circuit Boards
1. Space and Weight Savings
- Flex circuits are compact structures. They also decrease the space of the end product.
- Devices become lighter and more compact.
- Reduced bulk also means reduced shipping and handling costs.
2. Flexibility and 3D Design
- Almost any shape can be bent and folded into a new one. This is great for products with odd shapes or moving parts.
- Perfect among wearables, foldable phones, and small gadgets.
- It can wrap around corners or fit in tight spaces.
3. Durability and Reliability
- Flex circuits endure vibration, bending, and movement better than rigid boards.
- Fewer solder joints and connectors result in fewer breakages.
- Ideal for items that travel or are used in harsh settings.
4. Improved Heat Dissipation
Often more effective than many rigid boards, flex circuits dissipate heat better. This is crucial for maintaining device temperature, which in turn helps them last longer.
5. Decreased Assembly Errors
With fewer connections to manually make because bundles of wires are replaced with flex circuits, there are fewer connections due to fewer manual steps needed. This helps reduce errors during assembly or testing.
6. More Cost-Efficient Over Time
While the initial design of flex circuits may consume more time and money, they often prove to be more cost-effective in the long run. Their design eliminates the need for excess connectors, cables, and additional assembly steps.
In some situations, it can reduce wire costs up to 70 per cent.
Rigid-Flex Boards: The Best of Both Worlds
When a portion of the board needs to be stiff while other portions require flexibility, rigid-flex boards are a helpful solution. Such boards integrate both rigid and flexible sections into one board.
- It can be found in phones, cameras, and various types of military equipment.
- Provides complex shapes and reliable interconnections.
How Flex PCB Design Changes Everything
Fulfilling all benefits revolves around good flex PCB design, so their considerations include: board size, movements involved, and temperature or chemical changes.
How to Maintain Distance Between Signal Paths Short and Clear
Flex PCB suppliers with experience should alleviate your design concerns.
Flex PCB Assembly: Unique Skills Required
- Every step of a flex PCB assembly differs from typical boards. The materials are more delicate, and regular handling will damage them.
- Special machines prevent components from bending or tearing the board during placement and soldering.
- Routine quality checks guarantee every board meets performance standards.
- Having reliable circuit board suppliers in the UK or other locations enhances the accuracy of your assembly.
Applications of Flex Circuits
- Smartphones: The screen, battery, and camera are connected with flex circuits.
- Automobiles: Used in the steering wheel, dashboard, and even the seat sensors.
- Medical equipment, such as pacemakers and hearing aids, relies on flex circuits for comfort and reliability.
- Satellites: Flex circuits save a significant amount of weight while enduring the stress of launching into space and orbiting.
Things to Keep in Mind When Using Flex Circuits
Trustworthy suppliers: Collaborate with flexible PCB suppliers who possess expertise in your field of work.
- Consider movement: If your board is designed to flex and bend frequently, incorporate features that make it more resilient to these movements.
- Proxy test first: Before diving into full-scale production, build a prototype to identify and address any potential problems.
- Assembly considerations: Ensure that your assembly team is briefed on your strategy for the boards.
- Use rigid-flex if needed: For extra support or intricate shapes, consider using a rigid-flex board for added strength and flexibility.
Challenges to Look Out For
- Cost: Initially, designing and manufacturing flex circuits can significantly increase spending.
- Handling: They are skinny and fragile.
- Guidelines: Flex circuits have special requirements. Always adhere to your supplier’s guidelines.
Partnering with PCB Runner: Why Work with Them for Flex Circuits?
With flex circuits, modern electronics have unprecedented potential. They streamline products, making them lighter, smaller, and more dependable. The benefits are evident across the spectrum, from smartphones and automobiles to medical devices and even satellites, engineers gain refined design capabilities, reduced errors, and enhanced creative freedom.
However, to fully realise the advantages of flexible printed circuit boards, a suitable partnership is crucial. From flex PCB design and prototyping through full flex PCB assembly, PCB Runner has unparalleled experience and expertise. Their dedicated team provides custom support to the unique requirements of flexible circuits, ensuring seamless collaboration and project success.
When you select PCB Runner, you gain more than just a supplier. You are gaining a partner who looks out for your business outcomes, assists you in troubleshooting, and ensures your flex circuits are built to last. That’s how good ideas become great products.