Epec's Blog | Electronics Manufacturing Solutions

Flexible circuits offer advantages that rigid PCBs cannot, including improved reliability, reduced weight, and the ability to fit into compact or dynamic applications. However, these benefits often come with manufacturing considerations that can influence the overall cost of the finished circuit.

In the electronics industry, engineers regularly rely on STEP files to share 3D data between customers and external suppliers of components like cables, battery packs, machined parts, and more.

When starting a new PCB design or revision, considering the end application is usually at the forefront. Most of what we produce here at Epec is built to IPC-6012, the latest revision and Class II. Industry standards, as defined, and, of course, customer specifications, fabrication drawings, and the purchase order related to it are all taken into consideration, but these are typically part of the fabrication-to-quote and occur when the design is complete. So, what should be considered long before the quote and purchase?

Walk outside and look around. Chances are you will interact with several human-to-machine electronic interfaces before the day is over. You may use the keypad at a gas station, enter a code on a garage door opener, check a trail camera in the woods, or navigate using a chartplotter multifunction display (MFD) on a boat.

Space is widely recognized as one of the most unforgiving environments for electronics. Extreme temperatures, radiation exposure, vacuum conditions, and mechanical stress during launch all combine to create a unique set of challenges for printed circuit boards.

The first time you hold a finished high-density flex circuit in your hands, it can feel a little surreal. You know how much circuitry is packed inside, how many tradeoffs were made, and how much risk sat in every design decision. Yet the finished product is thin, light, and deceptively simple. That contrast is what makes high-density flex design so rewarding and so challenging at the same time.

From a PCB manufacturing perspective, designing for testability focuses on ensuring the circuit board can be efficiently inspected and verified at scale without slowing down production or increasing costs.

Battery management systems (BMS) are safety devices integrated into battery packs to monitor the cells during charging and discharging phases. These systems can activate safety controls when problems arise while logging data that you can use to evaluate the cell's stability. When functioning properly, the BMS can improve the efficiency and longevity of the battery pack. Unfortunately, BMS design flaws may cause serious risks and failures to cells.

Typically, when stiffeners and adhesives are thought of, they are only considered for flexible PCBs rather than rigid-flex PCBs. In reality, stiffeners can be applied to rigid-flex designs just as they are in flexible circuits.

Products that use battery packs may require certification through national and international quality and safety organizations. These regulations ensure that the battery packs meet compliance standards for packaging, transportation, use, storage, and disposal.