Flexrigid PCB – Rigid And Flexible PCB Combo

Flexrigid PCB – rigid and flexible PCB combo in one board
Rigid sections – hold heavy components (processors, connectors, batteries)
Flexible sections – bend and fold to fit tight enclosures
Eliminates connectors – no cables, no board-to-board connectors
Improves reliability – fewer failure points vs. rigid + cable + rigid
Saves space – folds into 3D shapes, replaces multiple boards
Reduces assembly time – one board instead of multiple parts
Lighter weight – no connectors, no cable harnesses
Ideal for – wearables, medical, aerospace, industrial
ISO9001 & UL certified – quality you can trust

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Flexrigid PCB – Rigid And Flexible PCB Combo

Flexrigid PCB (also known as rigid flex PCB) combines the best of both worlds: rigid FR4 sections for mounting heavy components, and flexible polyimide sections for bending and folding.

This single integrated board replaces traditional assemblies that use multiple rigid PCBs + connectors + cables – eliminating failure points, saving space, reducing weight, and simplifying assembly.

If your product needs to fold, fit into a curved enclosure, or withstand vibration, flexrigid is the answer.

What is a Flexrigid PCB?

Feature	Description
Rigid sections	Standard FR4 material – holds ICs, connectors, batteries, large passives
Flexible sections	Thin polyimide (Kapton) – bends, folds, twists
Continuous traces	Copper traces run from rigid through flex to rigid – no connectors
Single board	One integrated PCB – not multiple boards connected by cables

Think of it as: A rigid PCB that grows flexible “tails” where needed.

Flexrigid vs. Traditional Rigid + Cable + Rigid

Approach	Components	Connections	Failure Points	Assembly
Traditional	Rigid PCB #1 + Cable + Rigid PCB #2	2 connectors + cable	3+ (connectors, cable ends)	Complex
Flexrigid	Single integrated board	0 connectors	1 (the board itself)	Simple

Fewer parts = fewer problems.

Why Choose Flexrigid Over Traditional Assembly?

Benefit	How Flexrigid Delivers
No connectors	Eliminates connector cost and connector failure modes
No cables	No cable BOM, no cable assembly labor
Higher reliability	Fewer interconnects = fewer failure points
Space savings	Folds into 3D shapes – replaces multiple boards
Weight reduction	No connectors, no heavy cable harnesses
Better signal integrity	Continuous traces – no impedance discontinuities at connectors
Lower assembly cost	One board to place, not multiple boards + cables
Simpler inventory	One SKU instead of 3-5 SKUs

Typical Flexrigid Construction

Layer	Material	Thickness (typical)	Function
Coverlay (top)	Polyimide film	0.5 mil	Protects flex copper
Flex copper	Rolled annealed (RA) copper	0.5-1 oz	Signal traces in flex area
Polyimide core	Flexible base	1-2 mil	Insulation between flex layers
Flex copper (bottom)	Rolled annealed (RA) copper	0.5-1 oz	Signal traces in flex area
Coverlay (bottom)	Polyimide film	0.5 mil	Protects flex copper
FR4 rigid sections (additional layers on rigid areas only)	FR4 + prepreg + copper	0.4-1.6 mm	Component mounting, additional routing

Key point: The flex core runs continuously. FR4 is added only where rigidity is needed.

Flexrigid Layer Combinations

Type	Rigid Layers	Flex Layers	Total Construction	Typical Use
Simple	2 (top/bottom)	1	2 rigid + 1 flex	Wearables, simple sensors
Standard	4	1-2	4 rigid + 1-2 flex	Medical devices, smartwatches
Complex	6	2	6 rigid + 2 flex	Aerospace, industrial
Advanced	8+	2-4	8+ rigid + 2-4 flex	High-density, military

Most flexrigid designs use 4 rigid layers + 1-2 flex layers – this covers 80% of applications.

Flexrigid Design Considerations

Consideration	Recommendation	Why
Bend radius	Minimum 10x flex thickness (static), 30x (dynamic)	Prevents copper cracking
Flex layer count	1-2 layers typical	More layers = thicker = larger bend radius
Copper type	Rolled annealed (RA) for flex	ED copper cracks when bent
Via placement	Avoid vias in bend areas	Vias crack under flex stress
Component placement	Rigid sections only	Flex too thin for heavy parts
Coverlay	Use coverlay (not solder mask) on flex	Solder mask cracks
Stiffeners	Add under connectors on flex tails	Prevents flex damage during mating

Applications Best Suited for Flexrigid

Industry	Application	Why Flexrigid is Ideal
Wearables	Smartwatch, fitness band, AR/VR glasses	Fits curved wrist/head, holds battery/processor
Medical	Patient monitor, endoscope, hearing aid	High reliability, no connector failure, small size
Aerospace	Avionics, satellite electronics	Vibration resistant, weight reduction
Industrial	Robotics, CNC controllers	Dynamic flexing, rugged environment
Automotive	Camera modules, sensors	Vibration resistance, tight spaces
Consumer	Laptop, tablet, foldable phone	Hinge area – connects motherboard to display
Military	Portable radios, rugged devices	Reliability, shock/vibration resistance

Flexrigid vs. Other PCB Types

Feature	Rigid PCB	Flexible PCB (FPC)	Flexrigid (Combo)
Heavy component support	Excellent	Poor (needs stiffeners)	Excellent (on rigid sections)
Bendability	None	Excellent (entire board)	Excellent (flex sections only)
Space efficiency	Good	Excellent (folds anywhere)	Very good (folds where needed)
Connectors needed	Yes (board-to-board)	Fewer	None (rigid-to-rigid via flex)
Cost (low volume)	Low	Moderate	Higher
Cost (high volume)	Low	Low	Moderate (often lower total system cost)
Best for	Standard boxes	Simple bendable circuits	Complex folding with heavy components

Common Flexrigid Applications – Detailed

Device	Rigid Sections Hold	Flex Section Does
Smartwatch	Processor, battery, display driver	Wraps around wrist curve, connects to sensors
Hearing aid	Microphone, amplifier, battery	Folds to fit custom ear shape
Endoscope	Camera sensor, LED illumination	Bends through body cavity
Laptop	Motherboard components	Passes through hinge to display
Fitness band	Battery, vibration motor, optical sensor	Wraps around wrist
Automotive camera	Image sensor, processor	Connects through tight housing to main PCB

Why Choose Our Flexrigid PCB?

Feature	What You Get
True rigid-flex integration	Continuous traces from rigid through flex to rigid
RA copper standard for flex	Withstands repeated bending (dynamic flex)
No connectors needed	Eliminate connector failure points
Engineering support	Bend radius analysis, stackup design, material selection
Prototype available	Fast turnaround for design validation
Volume production	Scalable to your needs
ISO9001 & UL certified	Quality and safety guaranteed

Order Process for Flexrigid PCB

Upload Gerber files – specify rigid and flex layers, bend areas
Free DFM review – we verify bend radius, via placement, stackup
Receive quotation – based on your design complexity
First article (recommended) – 5-20 pieces for validation
Production – built to your specifications
100% electrical test – including flex continuity
Secure shipping

New to flexrigid? We recommend first article (prototype) before mass production. Flexrigid is more complex than rigid PCB – validate your design first.

Q1: What is the difference between flexrigid and rigid flex?

A: No difference – they are the same product.

Term	Meaning
Flexrigid	Shorter term – common in Europe and Asia
Rigid Flex	More common in North America
Rigid Flexible PCB	Full technical term
Rigid And Flexible PCB Combo	Descriptive term

All refer to the same technology: Rigid sections + flexible sections in one integrated board.

Q2: Can I put components on the flex section?

A: Yes, but with limitations.

Component Type	On Rigid Section	On Flex Section (no stiffener)	On Flex Section (with stiffener)
Small passives (0402, 0603)	Yes	Yes (careful)	Yes
Small ICs (SOIC, QFN)	Yes	Limited (avoid)	Yes
Large ICs (BGA, QFP)	Yes	No	Limited
Connectors	Yes	No	Yes
Battery, large capacitors	Yes	No	No

Best practice: Put all components on rigid sections. Use flex sections only for interconnect.

Q3: How small can the bend radius be?

Flex Thickness	Static Bend (one-time assembly)	Dynamic Bend (repeated, e.g., hinge)
0.1mm (1 flex layer)	1mm (10x thickness)	3mm (30x thickness)
0.2mm (2 flex layers)	2mm	6mm
0.3mm (3 flex layers)	3mm	9mm
0.4mm (4 flex layers)	4mm	12mm

Rule of thumb: Never bend tighter than 10x thickness. For moving applications, 30x thickness minimum.

Q4: Is flexrigid more expensive than rigid PCB?

A: Per board: Yes, flexrigid costs more than rigid PCB. But consider total system cost:

Cost Component	Rigid + Cable + Rigid	Flexrigid
PCB fabrication	Lower (2 boards)	Higher (1 integrated board)
Connectors (2-4)	Yes – significant cost	None
Cables	Yes – BOM + assembly	None
Assembly labor	Higher (multiple parts)	Lower (one board)
Inventory (SKUs)	3-5 SKUs	1 SKU
Total system cost	Often higher	Often lower

For many applications, flexrigid total cost is lower despite higher per-board cost.

Q5: What copper type should I use for flex sections?

A: Rolled Annealed (RA) copper – standard for all flexrigid.

Copper Type	Flexibility	Cost	Best For
Rolled Annealed (RA)	Excellent – bends without cracking	Higher	All flexrigid (recommended)
Electro-deposited (ED)	Poor – cracks when bent	Lower	Static flex only (not recommended for dynamic)

We use RA copper as standard for all flex sections.

Q6: Can flexrigid replace a cable between two boards?

A: Yes – that is one of the primary use cases.

Traditional approach	Flexrigid approach
Rigid PCB #1	Rigid section #1
Connector #1	No connector
Cable / Flex cable	Integrated flex section
Connector #2	No connector
Rigid PCB #2	Rigid section #2

Single board, continuous traces, no connectors.

Q7: What is the typical lead time for flexrigid?

A: Flexrigid takes longer than rigid PCB.

Quantity	Typical Lead Time
Prototype (5-20 pieces)	10-15 working days
Pilot (21-100 pieces)	12-18 working days
Production (101-1,000+ pieces)	15-20 working days

Quick turn available – contact us for urgent requirements.

Q8: Do you offer stiffeners on flexrigid?

A: Yes – stiffeners add rigidity to flex sections where components or connectors are needed.

Stiffener Type	Thickness	Best For
FR4 stiffener	0.1-0.5mm	ZIF connectors, general component support
Polyimide stiffener	0.05-0.2mm	Thin applications, dynamic flex
Metal (steel, aluminum)	0.1-0.3mm	Mechanical alignment, heat sinking

Specify stiffener location, material, and thickness when ordering.

Q9: What is the minimum order quantity (MOQ) for flexrigid?

A: No MOQ for prototypes – we accept as few as 5 pieces.

Quantity	We Accept
5-20 pieces (prototype)	Yes – for design validation
21-100 pieces (pilot)	Yes
100+ pieces (production)	Yes

For first-time flexrigid designs, we strongly recommend starting with a prototype (5-10 pieces).

Q10: How do I get started with flexrigid design?

A: Recommended workflow:

Design rigid sections first – place all heavy components
Design flex sections – connect rigid sections, ensure bend radius ≥10x thickness
Avoid vias in bend areas
Use RA copper for flex layers
Send Gerber files to us for DFM review
Order prototype (5-10 pieces) for validation
Test and approve before mass production

We offer free DFM review for flexrigid designs – we check bend radius, via placement, stackup, and material selection.

Shipping Terms

Shipping costs are paid by the buyer.
We normally ship via DHL, UPS, FedEx, or TNT.
Alternatively, you may provide your own courier account or arrange delivery to your freight forwarder in China.

For large-volume orders, sea freight is available.

Delivery to Port (FOB Terms)

When shipping to a port, Tengxinjie is responsible for transporting the goods to the departure port.
All customs clearance, ocean freight, insurance, and onward transportation after that point are the responsibility of the buyer.

Tengxinjie can recommend reliable local freight forwarders upon request.
With the buyer’s authorization, Tengxinjie may also assist in coordinating shipping, with all related costs charged to the buyer.

Notice

The above shipping information is for reference only.
Tracking details and shipment updates will be provided once the order has been dispatched.

PCBA Shipping Delivery

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Flexrigid PCB – Rigid And Flexible PCB Combo