Flexible Printed Circuit Manufacturers
Flexible printed circuits (FPCs) offer many advantages over rigid PCBs, including the ability to bend and conform to fit challenging mechanical packages. These unique capabilities come at a premium, however, and FPCs tend to be more expensive than their rigid counterparts. Accurately estimating the cost of a new flex circuit design early in the process can help engineers avoid sticker shock and effectively budget new programs. This guide explores the key factors that drive flex PCB cost and pricing, including layers, size, materials, tolerances and more.
The most significant factor influencing flex PCB cost is the amount of copper used. The thickness and quality of the copper foil, substrate and glue all directly impact flex PCB prices. Thicker copper and higher layer counts generally lead to more costly flex circuits. The type of etching used to remove the copper from the substrate and the amount of etching per layer also impacts flex PCB cost.
High-reliability flexible printed circuit manufacturers, typically used in medical devices or aerospace applications, require extra testing and materials that can dramatically increase costs. In order to meet Class 3 standards, the manufacturing process must be carefully controlled and adhered to stringent guidelines. Moreover, the specialized fabrication equipment and processes needed to produce Class 3 boards can also significantly increase flex PCB prices.
Cost Factors for Flexible Printed Circuit Manufacturers
Using high-speed connectors and high-density interconnects increases production costs as they require more copper layers to maintain signal integrity. In addition, the use of blind and buried vias adds to manufacturing complexity and expense. These additional steps require specialized solder masks, increased processing time and lower yields. Hence, it’s best to minimize these features where possible and stick with standard connectivity and layout requirements.
A flex PCB’s dimensions are another major factor in determining its price. A double sided (2 layer) circuit will be priced 1.5-2X more than an equivalent sized single layer flex PCB. This is primarily because of the extra materials required for each side.
Effective panel utilization is a key factor in saving flex PCB costs. The more circuits that can be nested on a larger panel, the lower the overall cost per circuit. The nesting density of a PCB is determined by panel borders and adherence to rules that define “keep out” regions for tooling and proper distances between nested circuits.
One of the primary reasons for the widespread adoption of flexible PCBs is their ability to streamline electronic assemblies. By replacing bulky wiring and connectors, flex circuits enable a reduction in weight and volume, which is critical in applications like aerospace, where every gram matters. Similarly, in consumer electronics, the use of flexible PCBs has been instrumental in creating ultra-thin devices, such as smartphones, tablets, and wearable gadgets.
FPCs are typically manufactured in panels and remain in that form through nearly the entire manufacturing process. In some cases, however, the flex circuit may be singulated for final assembly and other “personality” steps like connector attachment or stiffener mounting. This will affect both material and labor costs, as each individual flex circuit requires more processing and handling steps. It’s important to communicate these requirements clearly to your flex circuit manufacturer to optimize material and labor usage.
