Epec's Blog | Electronics Manufacturing Solutions

Flexible circuits support a wide range of interconnect options, including nearly all connector systems commonly used on rigid printed circuit boards as well as several solutions developed specifically for flexible circuit applications.

I love looking at data. Sounds weird, right? I guess it is because I have been working in the industry for so many years. I have seen the technology changes, and I just find it fascinating. In this blog post, we will recap the past, which some of the time creeps its way back to Epec, the present, and the future of printed circuit boards (PCBs).
Let’s get to it.

The last 18 months have been some of the most challenging that many of us have had to deal with both personally and professionally. It has often felt like we were riding waves, coming closer to things getting a little more normal, only to have them change radically. Looking forward to the next 18 months, I don’t see those changes getting any easier for us or our industry.

With advancements in rigid-flex PCB design technology, the use of laser-based systems in the manufacturing process are very common in the industry. Not having laser drilling and cutting available would place significant limitations on what could be accomplished in a design and what components could be used.

Cable assemblies are needed across various industries and are utilized in goods that include consumer electronics, industrial products, mil areo, and even medical devices. Low cost does not mean low quality; in fact, low-cost cables are qualified for use on many high-reliability applications.

Many flexible circuit board applications require designs to be exposed to and or operate continuously at elevated temperatures well beyond that of standard room temperature. These requirements are above and beyond the requirements of component or connector assembly.

Specific to medical devices, handheld electronics, rack-mounted equipment, and other instrumentation utilize membrane switches as a low-cost and high-reliability solution for keypad and button technologies. There are countless button and switch options available for the plethora of design requirements that exist. Medical professionals use these buttons as the primary way to interface and operate the device.

Flexible circuits can be manufactured using a wide range of material combinations, including different copper types, copper thicknesses, flex cores, coverlays, adhesives, stiffeners, pressure-sensitive adhesives (PSAs), shielding films, and flexible soldermasks. While this material flexibility supports a broad range of design requirements, selecting uncommon materials can significantly increase lead times.

Battery power requirements involve many factors. Beyond having enough power to run the application, customers also take into consideration battery capacity, charging/discharging rates, and environmental conditions that could impact the battery's functions. Before the battery packs development starts, there are other aspects about the power requirements that need to be evaluated. These aspects may impact the size of the battery, if there are any logistical restrictions that come into play and what types of certifications are required.

Advancing technology has impacted rigid-flex PCB designs in the same manner as rigid printed circuit boards. Increasing interconnect requirements and smaller form factors require higher circuit densities and increased layer counts. The impact of these elements on rigid-flex circuit designs is potential reliability issues both electrically and mechanically.