Flex-rigid PCBs combine the best of both worlds: the durability and component density of rigid boards with the flexibility and space-saving advantages of flex circuits. This hybrid technology is indispensable in applications where reliability and compact design are critical.
A typical flex-rigid assembly consists of:
Flex-rigid designs reduce connectors and cables by replacing multiple rigid boards with a single integrated structure. Devices can shrink 60% or more by eliminating bulky interconnects.
Fewer connectors mean fewer mechanical failure points — especially valuable in vibration-prone environments like aerospace or automotive systems.
Replacing multiple boards and connectors cuts labor time, assembly steps, and potential rework.
Flexible sections conform to the human body, making flex-rigid ideal for pacemakers, implants, and surgical tools.
Navigation systems, cockpit displays, and satellite electronics rely on flex-rigid PCBs due to their durability and weight reduction.
Smartphones, tablets, wearables, and cameras depend on flex-rigid connections for moving hinges, displays, sensors, and folding designs.
Minimum bend radius depends on copper thickness and material stackup. Designers must ensure the flex section is manufactured to withstand repeated bending.
Flex sections typically contain fewer layers than rigid sections. Careful stackup reduces stress at transition areas.
Sharp transitions between rigid and flex areas can introduce cracking. Reinforced fillets and curved transitions help distribute stress.
Polyimide-based materials are standard for flex circuits. Aerospace requires thermal resistance, while medical devices require biocompatibility.
Whether you're creating a new flex-rigid product or optimizing an existing design, Xekera’s engineering team can review your design for manufacturability (DFM) and improve long-term reliability.
Contact our team to discuss your PCB manufacturing needs and get a custom quote.
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