cost of manufacturing rigid flex boards
Rigid-flex circuit boards offer many advantages, but they come at a premium price compared to standard PCBs. The reason for this is the complexity and technology involved in creating a rigid-flex board. Understanding the key factors that influence the cost of manufacturing a rigid-flex board can help you reduce the final costs.
Layer count and wiring density directly impact the cost of a rigid flex board. A higher number of layers requires more copper traces, and these traces require a larger amount of materials to be fabricated. A higher trace density requires more fine-pitch surface mount technology and laser drilling, which adds to the overall fabrication time. In addition, advanced features such as blind and buried vias require specialized soldering techniques that increase production costs.
The type of flex material and stiffener used also have an effect on cost. For example, using thicker flex materials like FR-4 or polyimide increases the total thickness and cost of the circuit board. On the other hand, thinner flex materials like paper or textile composites are more affordable options that offer better flexibility.
What factors influence the cost of manufacturing rigid flex boards?
Economies of scale and order volume also contribute to the cost of a rigid-flex circuit board. The larger the order volume, the lower the per unit manufacturing cost. Prototyping or low-volume production can result in higher unit pricing.
A rigid-flex circuit board can be used in either static or dynamic applications. Static applications allow the flex area to be flexed only once in the end product, whereas dynamic applications need the flex area to flex repeatedly during operation. This flexing process changes the signal quality of the circuit board, and this can be reduced by using a thin insulating coverlay on the flex area.
Rigid-flex circuits can be finished with a variety of processes including gold plating, specialty coatings, and custom solder mask colors. These extra functions enhance the visual appearance of the final product but come at an additional cost to the manufacturing process. The most effective way to reduce the cost of a rigid-flex circuit is by optimizing the production process. This includes streamlining the production workflow, implementing automated systems, and providing extensive employee training to reduce mistakes that lead to rework and unnecessary expenses. Ultimately, reducing the cost of a rigid-flex circuit depends on your specific design requirements and project specifications. However, there are a few universal tips to follow that will help you save money: