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mokotechnologyltd · 5 years

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Rigid Flex PCB Design: Benefits and Design Best Practices

With the use of a rigid flex PCB(rigid FPC), flexible circuit substrates and rigid circuit substrates are covered together. Rigid-flex PCBs cross the limits of conventional rigid PCBs and the one of a kind properties of flex circuits that utilization high-flexibility electrodeposited or moved strengthened copper conductors photograph carved onto a flexible protecting film.

Flex circuits incorporate stack-ups produced using a flexible polyimide, for example, Kapton or Norton and copper-covered together through warmth, acrylic cement, and weight.

Likewise, with customary PCBs, you can mount segments on the two sides of the rigid board. As a result of the mix that happens among rigid and flex circuits, a rigid-flex configuration doesn’t utilize connectors or connecting cables between the segments. Rather, the flex circuits electrically interface the framework together.

The absence of connectors and connecting cables achieves a few things:

Improves the capacity of the circuit to transmit signals without misfortune

Accommodates controlled impedance

Eliminates association issues, for example, cool joints

Reduces weight

Frees space for different parts

Each rigid-flex PCB is separated into zones that element various materials and differing layer tallies. Rigid zones sometimes have more layers than flexible zones, and materials move from FR-4 to polyimide experiencing significant change zones.

Complex structures frequently change from rigid to flex and back to rigid on different occasions. As these convergences happen, the cover of rigid-flex materials requires repelling openings from the change zone to look after honesty. Likewise, numerous rigid-flex plans incorporate hardened steel or aluminum stiffeners that give extra support to connectors and segments.

Rigid FPC loads up cost a lot more than practically identical hardboards and are typically a few times the expense of a flexible circuit with stiffener.

Nonetheless, the expanded expense is legitimized with regards to explicit applications and situations, for example:

High-unwavering quality applications. In the event that a get together will be presented to inordinate or rehashed stun, or high vibration situations, connectors with flexible cables are more prone to fall flat. Rigid FPC gives incredible dependability in any event when exposed to extraordinary vibration and stun applications.

High-thickness applications. Inside a little fenced in area, it’s occasionally difficult to oblige every one of the cables and connectors that an electronic PCB configuration would require. Rigid FPC sheets can overlay into very little profiles, offering significant space investment funds on these occasions.

Five or more rigid sheets. In the event that your application will at last include five or more rigid sheets associated with each other with flex cables, a coordinated rigid flex arrangement is regularly the ideal and more financially savvy decision.

Diverse Design Rules Apply to Rigid-Flex PO Design

Various difficulties counterbalance the adaptability and flexibility that enable you to manufacture three-dimensional plans and items. Conventional rigid-flex PO plans enabled you to mount segments, connectors, and the frame for your item to the physically more grounded rigid piece of the get-together. Once more, as far as customary plans, the flexible circuit just filled in as an interconnect while bringing down the mass and improving the protection from vibration.

New item structures combined with improved flex circuit innovations have presented new plan rules for rigid-flex POs. Your structure group presently has the opportunity to put parts on the flexible circuit territory. Consolidating this opportunity with a multilayer way to deal with rigid-flex configuration enables you and your group to incorporate more hardware with the structure. In any case, picking up this opportunity includes a couple of difficulties as far as directing and gaps.

Flexible circuits consistently have twist lines that influence steering. On account of the potential for material pressure, you can’t put parts or vias near the twist line. Also, in any event, when segments are appropriately found, bowing flex circuits spots rehashed mechanical weights on surface-mount cushions and through openings. Your group can lessen those worries by utilizing through-opening plating and by reinforcing cushion support with extra .overlay to anchor the cushions.

As you plan your follow steering, pursue rehearses that lessen the weight on your circuits. Utilize incubated polygons to keep up flexibility when conveying a power or ground plane on your flex circuit. You should utilize bent follows instead of 90° or 45° edges and use tear examples to change follow widths. These practices reductions emphasize focus and shaky areas. Another best practice conveys worry crosswise over follows by amazing the top and base follows for twofold sided flex circuits. Balancing the follows keeps the follows from laying over one another a similar way and reinforces the PO.

You ought to likewise course follows opposite to the twist line to lessen pressure. When replacing rigid with flex and flex with rigid, the quantity of layers from one medium to the next may vary. You can utilize follow directing to add solidness to the flex circuit by balancing the steering for nearby layers.

Rigid FPC Design Guidelines

Extensively, a rigid flex configuration will intently look like a hardboard structure, with the flexible layers completely stretching out into the rigid regions of the board. So also to hardboard formats, a rigid flex creation bundle will incorporate Gerber layers, alongside drill documents, patch veil layers, classification, perimeter route records, a cover layer, and so on.

Ordinarily, there are some key contrasts between the manufacture bundles for rigid FPC’s and hardboard applications:

A rigid FPC, by and large, has a lot more measurements on it, and ought to deliberately characterize the necessities, as these sheets are commonly utilized in 3D applications. It ought to likewise precisely characterize the rigid to flex progress zones, as these are not constantly clear when surveying the Gerber layers alone.

The material layup in rigid flex sheets is basic, and ought to be worked out in collaboration with your fabricator. Your fabricator can assist you with settling on the correct decisions in materials based on your necessities, for example, UL combustibility rating, least twist radii required, mechanical contemplations, impedance control on both flex and rigid layers, RoHS affirmation, lead-free get together similarity, and different contemplations.

Rigid flex sheets, as a rule, require extra layers in the Gerber documents. Layers 1 and X will have weld veil layers, yet you will likewise require artwork layers that characterize the cover layer and bondply segments (whenever expected) of the board, and how much each go into the hardboards. IPC 2223 suggests 0.100″ however your fabricator might have the option to oblige not as much as that.

What affects the design of rigid-flex PCB

Electromechanical Factors Influence Design

At the point when you plan rigid-flex PCBs, think as far as electromechanical factors that influence the flex circuit and the rigid board. As you construct your structure, center around the proportion of curve range to thickness. With flex circuits, tight curves or an expanded thickness at the twist region increment the odds for disappointment. Fabricators suggest keeping the curve span at least multiple times the thickness of the flex-circuit material and building a “paper doll” of the same circuit to figure out where twists happen.

You ought to abstain from extending the flex circuit along with its external twist or packing it along with the inward twist. Expanding the curve edge past 90° builds extending at one point and pressure at another point on the flex circuit.

Another key issue in rigid-flex unwavering quality is the thickness and kind of conductor found in the twist locale. You can diminish thickness and mechanical worry by lessening the measure of plating on the conductors and utilizing cushions just plating. The utilization of substantial copper, gold, or nickel plating diminishes flexibility at the curve and permits merlinnical stress and cracking to happen.

Material Lay-up Considerations

Rigid FPC material layups intensely impact cost, manufacturability, and last PCB performance, so it’s fundamental to invest energy deciding the perfect material set. For example, controlled impedance, opposition, and current-conveying necessities are terrifically important contemplations that influence both copper loads and material choice.

A PCB architect ought to collaborate with their board fabricator to examine these factors, so the subsequent plan agrees to all flag honesty necessities. When the creator has performed starting computations, the fabricator can check them, and give a more precise displaying of the impedance qualities of the board, and material set required to accomplish those qualities.

On the off chance that impedance attributes are not excessively basic, our you are searching for the least cost, most stable rigid-flex plan proposals. Rigid-Flex program offers the most reduced generally speaking material expenses for rigid-flex plan, while additionally giving a sheltered beginning stage for planners who are new to the rigid-flex structure.

In the event that you may want to get a snappy gauge on how much your rigid-flex configuration may co* attempt our Rigid-Flex Cost Estimator. The rigid-flex cost estimator will take your necessities and will give you an expected expense for low-level generation amounts. It is an incredible beginning stage to check whether your plan is monetarily attainable with your program prerequisites.

The rigid segments of rigid-flex sheets are generally 20 layers or less. There are times when they have more, yet generally, more than twenty layers are really uncommon. The hardboard areas don’t all must have a similar layer tally. For instance, you could have one rigid segment with 16 layers of hardware and one with 12. For any amount of time that the material layup is comparative for each and the loads up have a similar generally thickness, there will be no assembling issues. Every so often, a configuration may utilize hardboards that contrast in thickness, however, such setups are significantly more hard to make and different choices ought to be considered.

The flexible areas of rigid-flex sheets are typically one (singlet), two (doublet), three (triplet) or four layers (quad development). There are times when an originator needs more than four layers over the flexible areas of the load up, yet are quite often unbonded. Reinforced flex areas that have more than four layers can be very impervious to twisting as well as flexing. Copper loads on the flexible layers of the rigid-flex sheets are most regularly half and one-ounce loads.

Once in a while the electrical interest requires two-ounce loads. In those cases, the fashioner should work intimately with their fabricator to pick the correct no stream prepreg, to satisfactorily fill the thicker circuits in the hardboards. No stream prepreg, by configuration, doesn’t prefer to stream and two-ounce hardware can exhibit a few difficulties. Three-ounce copper weight is once in a while utilized and can show considerable issues in assembling for a similar explanation.

Rigid-Flex PCB Design Requires Teamwork

New PCB configuration instruments enable your plan group to deal with different layer stacks, visualizing 3D electromechanical structures, check configuration controls, and reenact the activity of flex circuits. Indeed, even with these apparatuses close by, the effective structure of a rigid-flex PCB relies upon teamwork between your group and fabricators.

Teamwork must start at the most punctual phases of the undertaking and proceed all through the structure procedure and relies on steady correspondence.

Moko Technology rest you assured with strong capacities and expertise if you’re in need of rigid FPC, welcome to visit https://www.mokotechnology.com/

#rigidpcb rigidflexpcb rigidpcb pcb mokotechnology

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richardlawson1489-blog · 8 years

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#PCB #PCBManufacture #RigidPCB #USA

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agilecircuit · 6 years

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PCB manufacture and assembly in one stop solution #circuit #electronic #manufacturing #turnkey #assembly #lighting #manufacturer #printedcircuitboard #pcb #pcbassembly #pcba #circuitboard #printed #rigidpcb #flexiblepcb #ems #oem #pcbmanufacturing #factory #pcbmanufacturer #pcbsupplier https://www.instagram.com/p/BnavbeKAtFL/?utm_source=ig_tumblr_share&igshid=1dubuvvx9qxha

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mokotechnologyltd · 5 years

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Rigid vs. Flexible PCBs: Which One is Best?

A rigid-flex printed circuit board (PO) is a half and half circuit board plan that incorporates components from both hardboard and flexible circuits. Rigid-flex PCBs are rigid at certain focuses on the board and flexible at others. Along these lines, rigid-flex PCB can be collapsed or consistently flexed while keeping up the state of territories that need additional support. The circuits are regularly multi-layered and are included flexible circuit substrates got together with rigid sheets. The flexible layers are covered entirely and inside infiltrate the rigid areas of the PCB.

One of the key advantages of a rigid-flex PCB is its thin profile. The standard dielectric in flexible circuits is .001 – .002″, settling on it an amazing decision for ultra-slight—and ultra-light—bundling needs. Adhesiveless overlays, HDI, and flimsy copper layers make it perfect for exceptional line innovation, giving you the Smallest, most lightweight, and lightest answer for your circuit plans.

Rigid-Flex PCB Types

Rigid-flex PCBs support two essential application types: flex to introduce and dynamic flex. Flex to introduce is the most well-known kind of rigid-flex PCB application. In this circuit application, the board overlays just once when the gadget is amassed or evacuated. In actuality, the flex some portion of the board stays stable all through use, despite the fact that some development may happen on account of high vibration applications. Thus, it is some of the time vital for a PCB to have the option to create and more than once twist during final result use. This kind of circuit application is known as a unique flex. It requires exceptional thought to guarantee the flexible portion of the board can withstand rehashed wear. At the point when planned with a proper twist sweep, these circuit sheets can be trusted to keep going for a huge number of flex cycles without issue.

The Feature Of Rigid Flex PCB

All lines are arranged, which can spare the association work of overabundance line;

Less weight and space prerequisite makes these rigid flex circuits a perfect decision for medicinal applications, for example, pacemakers.

It can viably diminish the volume of the item, and more helpful to convey.

It can lessen the heaviness of the firm item;

It can improve the delicateness and reinforce the get together of the three-dimensional space in the constrained space.

Rigid-flex PCB Applications

While they come at a greater expense, rigid-flex sheets are unbelievably adaptable and can be tailored to applications over a wide scope of businesses. They are profoundly appropriate for military, aviation, and therapeutic gadgets, yet they can likewise be actualized towards certain business items. A few conditions make Rigid-Flex PCBs as an ideal arrangement. In such circumstances, these sheets are worth the venture, yet in addition, might be the most financially savvy decision. These include: • High-stun and high-vibration situations. Rigid-flex PCBs are exceptionally stunned safe and can get by in high-stress situations that would some way or another cause gear disappointment. • High-exactness applications where unwavering quality is more important than cost contemplations. In circumstances where a link or connector disappointment would be hazardous, the more strong rigid flex PCBs are ideal. • High-thickness applications. A few congregations do not have the imperative surface zone for all the vital connectors and cables. A rigid flex circuit can streamline space to take care of this issue. • Applications requiring different rigid sheets. At the point when congregations become busy with more than four associated sheets, it might be ideal and more practical to supplant them with a solitary rigid flex PCB.

Advantages

More extensively, rigid flex PCBs have the accompanying focal points: • Endure significant levels of stun and vibration • Endure countless flex cycles • Decrease bundle weight • Increment circuit thickness • Lessening important gathering tasks. Rigid flex circuit gatherings are perfect for lessening or potentially dispensing with connectors, just as the labor, yield, transmission, and unwavering quality gives that are inalienable in their application. Along these lines, any get together that can profit by these highlights can profit by a rigid flex PCB.

Commonly used material of flex-Rigid PCBs

The performance of rigid flex pcb relies upon that of substrate material of them that fundamentally contains flexible dielectric film and flexible glue film. As the main kind of flexible substrate material, flexible dielectric film, for the most part, incorporates polyester (Mylar) that is generally utilized in low-finished results, polyimide (Kapton) that is the commonest type, and fluoropolymer (PTFE) that is normally utilized in military and aviation items.

As those three kinds of flexible materials are looked at, polyimide highlights the most elevated dielectric steady with brilliant electrical and mechanical properties and high-temperature obstruction however is costly and simple to absorb dampness. Comparative with polyimide as far as performance, polyester, notwithstanding, includes awful high-temperature opposition. Polytetrafluoroethylene is essentially utilized in high-recurrence items with low dielectric constant.

The main material adding to flexible glue film contains acrylic corrosive, epoxy and polyester. Acrylic corrosive and polyesterimide include incredible attachment, high flexibility and generally high synthetic obstruction and warmth opposition. Notwithstanding, it includes a moderately enormous coefficient of warm extension so its inside thickness ought not to be over 0.05mm. Epoxy gum includes a terrible bond and is, for the most part, applied to stick covering layer and inward layer. Moreover, it highlights such a low coefficient of warm extension that it’s advantageous to warm stun opposition improvement of plated through gaps.

Flex Circuit Overlay

Flex circuit overlay, or coverlay, as it’s likewise known, is a cover procedure utilized for exemplifying and securing the outer hardware of a flex circuit. A flex circuit’s coverlay film is like a rigid PCB’s weld veil, with one major difference, the coverlay film is flexible! According to allflexinc.com, “The coverlay film is by and large a polyimide film that is covered with a thermoset cement. Film thicknesses extend from .0005″ to .005″ with .001″ and .002″ the most well-known.”

When to Use Rigid & When to Use Flexible

Rigid flex PCBs ordinarily cost not as much as flex circuits. I state “normally” in light of the fact that when considering the complete expense of possession there are a few applications that, when utilizing flexible PCBs, might be more affordable contrasted with utilizing rigid PCBs. To get a genuine and precise comprehension of the complete expense of proprietorship, you first need to welcome the way that flex circuits may take out the requirement for parts, for example, connectors, wire outfits, and other Numerous electronic gadgets (PC and personal computers, sound consoles, strong state drives (SSDs), level screen TVs and monitors, kids’ toys and different electronic devices) utilize rigid PCBs rather than flexible PCBs. Furthermore, flex circuits might be found in ultra-conservative or potentially elite gadgets, including GPS units, tablets, PDAs, cameras, and wearables. More noteworthy modernity isn’t the main motivation to utilize flex circuits; low-tech applications may use flex circuit innovation now and again in light of the fact that it makes the establishment a lot simpler.

Understanding when to utilize both

Presently you need to comprehend when to utilize a rigid PCB and when to adhere to a flexible PCB. Obviously, the rigid ones cost not as much as flex circuits. On the other hand, the expense of proprietorship and the application can decide the amount you need to spend. There are occurrences where the utilization of flex circuits can diminish the costs you cause. On the off chance that you might wish to comprehend the all-out cost of proprietorship, at that point you should recognize a couple of actualities. Flex circuits dispose of the requirement for a few segments like connectors, wire tackles, and other circuit sheets. In the event that you address flexible circuit board producers, at that point they will say something very similar. Certainly, a flex circuit and a rigid flex PO can be utilized together—as a brought together PCB—if the need emerges. This methodology, maybe, gives the best of the two worlds.

The Differences

When planning rigid PCBs, certain structure rules must be pursued, including least gap sizes, least space and follow width, least separations to board edges, and copper and in general structure thicknesses. Also, many assembling procedure steps are shared among rigid and flexible PCBs. Such procedure steps incorporate the penetrating and plating of gaps and vias, photograph imaging and advancement, the drawing of copper follows, cushions, layouts, and planes, and the warming (heating) of the circuit loads up for the motivation behind expelling dampness from the PCBs. Now in the assembling procedure, rigid PCBs head to the weld veil station while flex circuits go to the coverlay station.

RigidFlexible

DefinitionA rigid-flex circuit is a half breed development of the FPC board and FR4 board, it is covered together into solitary structures. That is, both rigid and the flex parts are planned with follows and they are associated, the FR4 doesn’t act just as a stiffener, there would be circuit both on FPC and FR4 board.FPC (Flexible printed circuit) alludes to a slight protecting polymer film having conductive circuit examples appended. The most preferred position for FPC is flexibility, which enables it to be great association inside a conservative space or parts that need to bow.

Production & PriceWhile rigid-flex PO is similarly mind-boggling, they need an overlay of the FPC circuit and FR4 load up ordinarily when manufacturing rigid-flex PCBs, the factory needs both rigid PCB generation machines and flex PO creation machines, with more than 50 procedures, the quality control will be more troublesome. On account of the generation trouble, the rigid-flex PO is normally significantly more costly than some other sheets, for example, FR4/FPC with stiffener,they are typically just utilized in quality requests activities, for example, military tasks, satellite.It’s basic for the generation procedure of rigidized flex development, the factory will bond stiffeners after the FPC delivered. As the modest value, the FPC is generally utilized and the expense is moderately low. FPC is more typically utilized on customer electronic items, for example, cell phones, workstations.

MaterialIt contains flexible dielectric film and flexible cement film.The flexible film, for the most part, incorporates polyester (Mylar) that is typically utilized in low-final results, polyimide (Kapton) which is the commonest type, and the fluoropolymer (PTFE).

What are the means to make a rigid-flex PCB

Manufacturing rigid-flex structures are more mind-boggling than making a basic rigid plan since 3D space is required so as to build up a rigid flex structure.

The base material of a rigid portion is made out of FR4 and the flex portion is comprised of polyimide and after that copper foil and coverlay holding film are applied.

In the initial step of assembling rigid flex PCB, accessible glues are applied on a copper layer.

After that slender layer of copper foil is covered on the glues. Copper plating can likewise be utilized instead of overlay process.

The next step includes the boring of little gap on the flex substrate. Laser penetrating is most appropriate for making exact and precise openings.

Copper is stored into the gaps when they are penetrated into the flex design. This procedure is known as the through opening plating in which copper is synthetically plated.

In the subsequent stage, Photosensitive engraving opposes covering is applied on the flex surface. The window ornament coat technique is perfect for this procedure.

The copper film is appropriately carved once the covering is applied. From that point forward, draw oppose is expelled from the circuit board.

In the subsequent stage, coverlay insurance is applied on the top and base layers of the flex substrate. Polyimide material is a perfect decision for utilizing as a coverlay security.

Blanking is a subsequent stage in which flex substrate is cut dependent on the plan necessities. Kick the bucket set and Hydraulic punch are the most ordinarily utilized procedures for cutting the flex. These techniques include the cutting of different flex with high exactness and precision.

In the last advance, a flex board, produced using the blanking procedure, is overlaid between the rigid layers which result in the last item that can be electrically tried to make it accessible for the electronic reason.

Rigid Flex PCB Cost

The essential purpose behind the more costly PCB tooling charges related to flex or rigid-flex circuit sheets truly comes down to the measure of physically made building programs a particular structure may have. The other explanation is the volume; however underway volumes we commonly observe that most clients recover the extra cost in 2000 pieces or less.

The other factor in the expense of tooling pursues comes to volume. For rigid-flex and additionally flex models and little volume runs, most are made with laser cutting or some kind of mechanical directing. This is utilized to make the surface mount includes in the coverlays, part diagram, and whenever required, the framework of the stiffeners.

Electrical testing on these lower volumes is ordinarily finished with a flying test. In volume creation of flex and rigid-flex circuits, you have to switch over to steel rule passes on or male/female punch and bite the dust sets. This steel rule kicks the bucket and is regularly more costly to make refrains the laser cutting system. The electrical test apparatuses are likewise exchanged over to a hard-wired test, which can be more labor serious. Both of these factors can include an underlying forthright cost, yet it considers a generous decrease to the unit cost of the part when you are managing higher volumes.

Layers are the most important factor, if single-sided flex is sufficient, never attempt more layer

Flex Board types: Single Pieces or in Panel, when doing Flex PCB Cost Estimator, consider material use rate, flex PC material is move unit, one of side can’t be more then 250mm, when creation, we will set working board size, if waste parcels, this will ascertain into flex PCB cost .

Min Track/Spacing, 2-3mil.

Min Hole Size, not be excessively little, 0.25.

Gold Fingers, two choices for flex PCB gold finger, hard gold or inundation gold, hard gold is significantly more costly.

Copper Thickness: 1/3 oz is normal, keep flexible, not propose overwhelming copper.

Stiffener, Flex PO connector has 3 choices to choose stiffener: Fr4 stiffener, Aluminum stiffener, Pi stiffener, in the event that you Plug recurrence, recommend utilize harder stiffener.

Surface Finish: Normal is drenching gold.

Size: more material utili7ntion rate, more less expensive.

Quantity: The more the less expensive

In Conclusion

Despite the fact that both rigid and flexible printed circuit sheets on a very basic level fill a similar need—connecting different electrical and mechanical segments together—the two innovations have their place throughout everyday life. While a significant number of similar plan rules are utilized with both rigid and flexible PCBs, flexible PCBs require some extra rules because of their extra assembling procedure steps. Furthermore, despite the fact that rigid PCBs may appear, in any event at first, to cost less, one should consider a plan’s all out the cost of proprietorship before announcing that flex circuits are excessively costly.

Everything thought of it as’, important to take note of that not all board houses are fit for assembling flexible PCBs. Prior to beginning a flex circuit plan, you should meet various board houses and talk about flexible PCB manufacture choices and related costs.

This article is from https://www.mokotechnology.com/rigid-flex-pcb-vs-flexible-pcb/

If you are looking for a PCB manufacturer, then we are your best choice!

#PCB flexpcb flexiblepcb rigidpcb mokotechnology

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mokotechnologyltd · 5 years

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Introduction of rigid PCB

Rigid PCB is an inflexible and solid Printed Circuit Board. We cannot bend them or force them out of shape. It is very difficult to fold them or modify them after their manufacturing. Rigid PCB is made from the solid substrate and they have copper tracks. They also include component layouts where we solder active & passive components through automated or manual techniques. The aim of this article is to guide you regarding Rigid PCB and tell you everything you need to know.

Features and Benefits of Rigid PCB

Rigid PCB offers many benefits when we use them for commercial and industrial electronic systems. We mainly choose them because,

We can manufacture them to fit into any device instead of designing a device according to the specifications of the PCB.

They are compact and lightweight. Therefore, they have a smaller size.

We can design them without contact crimps or connectors. So, they are reliable when it comes to high-end applications.

Since they have a lesser number of interconnects, hence they have a smaller chance of circuit failure.

They can withstand extreme temperatures because of their thermally stable structure. This advance property makes them a suitable option for aerospace and military applications.

They require lesser material for manufacturing. Therefore, expenses for material procurement and manufacturing are reduced.

Rigid PCBs offer good resistance to ultraviolet radiation, aggressive oils, and harsh chemicals. Hence, we can use them in marine applications.

We can design them such that we can easily surface mount them on both sides.

It is possible to customize a rigid PCBs to meet special industrial requirements.

We can manufacture them robustly to withstand vibrations, high impact, shock, and other aggressive conditions.

Applications of Rigid PCB

We tend to use Rigid PCBs when we are looking for maximum adaptability and reliability. If we don’t want the circuit to bend under the applied stress then we use Rigid PCBs. They have evolved at an enormous pace in the last few years and are now used in a variety of applications. This has led to an increased demand for Rigid PCBs, the likes of which are unprecedented.

Computer Electronics

Most of the computer components today rely on Rigid PCBs. For instance, computer hard drives revolve at very high speeds. Therefore, it is necessary that their adjoint circuit can withstand the consequent vibrations. Also, if the hard drive operates for a long time then it will get very hot. So, the PCB will have to face high temperatures. Therefore, we use Rigid PCBs because they can withstand these extreme conditions and the data is safely read and written on the hard drive.

These conditions are not subject to computers only. Rather, most of the electronic systems today like PlayStation, televisions, microwaves, refrigerators, and printers have these extreme conditions. Therefore, we have to use rigid PCB because their performance isn’t affected by extreme conditions.

Automotive Electronics

Most of the electronic hardware in modern automobiles rely on rigid PCBs. These include anti-lock braking systems, instrument panels, engine management units, airbag controllers, and dash systems.

We can design rigid PCBs to fit into small spaces or irregularly shaped craters. This provides us flexibility in the manufacturing process. We can sync the circuits with other electronic modules without using bulky connectors or cable ties. Weight is also a concern in many vehicles. Therefore, even a small addition can make a huge difference. Rigid boards allow us to effectively address these concerns as compared to conventional alternatives.

The electronic components in automobiles have to withstand extreme conditions. They experience extreme vibrations because of driving on the rough terrain. They are also exposed to extreme cold and heat from the air conditioner and the engine. Therefore, we must use rigid PCBs because they are the only ones capable of withstanding these conditions.

Smartphones

Smartphones are handheld, therefore we need to make them small, portable, and lightweight. So, we need a PCB which can perfectly sync the core components and hold them together. Therefore, rigid PCBs are an ideal candidate for smartphones.

We take our smartphones everywhere with us so their hardware must withstand the changing environment and temperature fluctuations. Therefore, we cannot use conventional PCB. So, we look towards a rigid PCB.

Nowadays, most smartphones are water-resistant and come with water-repelling cases. These allow a smartphone to work even when it is submerged in water or any other liquid. These service conditions are too demanding for conventional PCBs. Hence, we have to once again rely on rigid PCBs.

The material of Rigid PCB

The performance of rigid PCBs depends mainly on the substrate material which constitutes the adhesive and dielectric films. We mostly use Polyester for manufacturing low-end rigid PCBs. However, for manufacturing high-end rigid PCBs we use PTFE and Kapton. These are a bit expensive and are therefore deployed in aerospace and military applications.

When we compare these three materials, we come to see that Kapton has the highest dielectric constant. Therefore, it has superior mechanical and electrical properties. These properties sustain even in high temperatures. However, these are more expensive and readily absorb moisture. In comparison, polyester doesn't absorb moisture but it can't sustain its performance at extremely high temperatures. We mainly use PTFE in high-frequency applications that require low dielectric constant.

Manufacturing of Rigid PCB

There are different technologies for manufacturing rigid PCB and we choose between them according to our requirements. Now we will take a look at some of them.

Layer Stack up Technique

One way to manufacture rigid PCBs is by stacking up layers of rigid material in a selective and orderly manner. We can then use through-holes for establishing connections between the layers. We can easily reduce the volume of the finished electronic product by using the stack up technology. This will allow rigid PCBs to withstand extreme contact pressure and intense heat strokes. Therefore, we will get better performance and improved reliability.

Industrialists came up with the idea of rigid PCB in the 70s. Since then, the stack up technology is widely deployed for fabricating rigid PCBs. With the passage of time, many people came up with different innovations and the standard procedure was modified. Today, the most reliable variant is to apply glass epoxy resin (FR4) on a rigid board. Also, we apply a solder mask for protecting the circuit pattern on the rigid board.

Substrate Material

We mostly use Kapton as a substrate material for making the core. We use a mixture of Kapton and acrylic for making a film that protects the circuit pattern. In this case, the adhesion is dependent on the prepreg which has a low flow rate. We laminate all these elements so that we can fabricate the rigid PCBs.

Rigid substrate material allows for excellent dielectric properties which are suitable for impedance control and high-frequency signal transmission. Therefore, they can also withstand the extreme environment, radiations, and temperature shocks. Hence, we can ensure that the electronic product will run smoothly.

Quality Control

Rigid PCBs can solve the issue of thermal dissipation and loose contact by taking care of the connectors. Therefore, we can improve the overall reliability of the electronic product. Towards the end of the manufacturing process, we can try to bend the PCB. If it is successfully bent then it doesn’t meet the electrical and mechanical performance standards. This allows us to effectively perform quality control and modify the process if need be. Therefore, we can achieve the required degree of rigidity and consequently the required level of performance.

Shortcomings of the Stack Up Technique

When we manufacture rigid PCBs through the stack-up technique then they have comparatively high density and low yield rate. Therefore, it is difficult to repair them in case of a breakdown. We need to embed the rigid base within the substrate material during the manufacturing process. So, there is a large wastage of raw material and the manufacturing process becomes difficult. Therefore, we need some new technology for manufacturing rigid PCBs.

Embedding Technique

When we use the embedding technique, we integrate the circuit units into internal rigid boards. So, after that, we can go about the bottom-up approach. So, the interconnections are unavailable between the two layers and the connection is mainly dependent on the buried VIAS and blind VIAS. Embedding allows us to reduce the raw material wastage and improve the performance of the rigid boards.

Since we are layering up in the embedding technique, therefore the effective surface area is much larger. So, the usage rate of the substrate material is improved. We can further enhance this by using through-holes to establish a firm connection in the circuit.

Embedding technique also allows us to address the problems of high density. It also offers a relatively easier manufacturing process. Therefore, we prefer this technique over the stack-up technique.

If you are looking for a reliable and durable rigid PCB then you are in the right place. MOKO Technology is a renowned name in the PCB industries and we have a wide experience in manufacturing rigid PCB. Our products are of premium quality and our services are of a superior standard. We have a large setup with mass production capacity. So, we can offer customized products as per your needs. Feel free to contact us for a quote or any further questions.

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