Rigid-flex circuits combine rigid board areas and flexible interconnections in one integrated design. They can help customers fit electronics into tight spaces, reduce separate cables and connectors, and position components across different planes within a product.
Flex Circuit Solutions works with OEMs and contract manufacturers on new rigid-flex designs and second-source programs. We support DFM, stack-up and material review, quoting, and production coordination from prototype through volume production. Our team reviews bend requirements, rigid-to-flex transitions, via structures, component placement, and assembly needs to develop a construction that fits both the product and the manufacturing process.
Have a rigid-flex design or existing part to review?
Rigid Flex Circuits
Rigid-Flex Design & DFM Support
Rigid-flex designs require the rigid and flexible areas to work together electrically and mechanically. FCS reviews the construction early, while there is still room to address features that could affect fabrication, assembly, or long-term performance.
Stack-up and materials: We review rigid board materials, flex layers, copper thickness, and layer arrangement against the electrical and mechanical requirements. The goal is a construction that supports the intended bend and can be produced consistently.
Bend areas and transitions: Bend radius, copper routing, and the transition between rigid and flexible sections need particular attention. We look for features that could concentrate stress or create problems when the circuit is formed and installed.
Vias and interconnects: We evaluate plated through holes, blind or buried vias where needed, pad locations, and routing through each section. Via placement and the required layer connections can have a significant effect on the proposed stack-up and manufacturing process.
Assembly requirements: Component placement, connector locations, stiffening, and handling during assembly are considered alongside the bare circuit design. We also review how the finished circuit will fit and connect within the customer’s product.
Working through these details during DFM helps establish a practical design and production plan, whether the project is a new rigid-flex circuit or the qualification of a second source.
Rigid-flex construction can connect component-bearing rigid sections through an integrated flexible circuit. It is especially useful when the product’s shape, available space, or connection requirements make separate boards and cables difficult to manage.
Compact, three-dimensional packaging: Flexible sections allow rigid boards to be positioned on different planes or folded into a constrained enclosure.
Fewer separate interconnects: Integrating the connection between boards may reduce the need for cables, connectors, and associated assembly steps.
Design integration: Rigid areas support component placement while flexible areas route signals between them. Their shapes and locations can be developed around the product’s mechanical design.
Application-specific construction: Layer count, materials, via structures, and bend requirements can be evaluated together rather than treating the board and its interconnects as separate parts.
Rigid-flex is not the right choice for every product. FCS helps customers assess whether its packaging and integration benefits justify the proposed construction and production approach.
Where Rigid-Flex Circuits Add Value
Rigid-Flex Applications We Support
Rigid-flex circuits are often considered when a product needs component-bearing boards connected within a compact or complex enclosure. FCS works with customers to evaluate the electrical, mechanical, assembly, and quality requirements for applications such as:
Medical devices: Class III implantable devices, endoscopy systems, surgical robotics, imaging and diagnostic equipment, and patient monitoring systems.
Aerospace and defense: UAV systems, munitions, instrumentation, display interconnects, and communications equipment, subject to each program’s sourcing and quality requirements.
Automotive: Sensors, controls, lighting systems, and electronics designed for limited installation space.
Industrial electronics: Robotics, measurement equipment, machine controls, and systems with multiple connected circuit sections.
Commercial electronics: Displays, communications devices, wearables, and other products where integrated board connections can simplify packaging.
Each program calls for its own review of stack-up, bend conditions, assembly, and production needs. We work with customers to determine whether rigid-flex is a practical fit.
