Rigid Flex Board – Rigid Flexible PCB Fabrication

Rigid Flex Board – rigid flexible PCB fabrication
Rigid sections + flex sections – one integrated board
Rigid sections – FR4 material, holds heavy components (ICs, connectors, batteries)
Flex sections – polyimide material, bends and folds to fit enclosures
Eliminates connectors – no board-to-board connectors or cables
Continuous traces – copper runs uninterrupted throughout the board
3D packaging capable – folds to fit complex shapes
High reliability – fewer interconnects = fewer failure points
Custom fabrication – built to your exact specifications
ISO9001 & UL certified – quality you can trust

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Rigid Flex Board – Rigid Flexible PCB Fabrication

A Rigid Flex Board (also known as a rigid flexible PCB) is a hybrid printed circuit board that integrates rigid FR4 sections for component mounting and flexible polyimide sections for bending and folding – all in a single, continuous board.

Unlike traditional designs that use multiple rigid PCBs connected by cables and connectors, a rigid flex board eliminates connectors entirely. Traces run continuously from rigid section to rigid section through the flexible polyimide core.

If your product needs to fold, fit into a curved enclosure, or survive vibration, rigid flex board fabrication is the solution.

What is a Rigid Flex Board?

Feature	Description
Rigid sections	FR4 material – supports heavy components (processors, connectors, batteries)
Flex sections	Polyimide (Kapton) – bends, folds, twists
Continuous traces	Copper runs uninterrupted from rigid to flex to rigid – no connectors
Single board	One integrated board – not multiple boards connected by cables
Custom fabrication	Built to your exact Gerber files and specifications

Think of it as: A rigid PCB that grows flexible tails where you need them.

Rigid Flex Board vs. Traditional Assembly

Approach	Components	Connections	Failure Points	Assembly	SKUs
Traditional	PCB #1 + Cable + PCB #2	2 connectors + cable	3+	Complex (multiple parts)	3-5
Rigid Flex Board	Single integrated board	0 connectors	1	Simple (one board)	1

Why Choose Rigid Flex Board Fabrication?

Benefit	How Rigid Flex 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
Design flexibility	Rigid sections can be different sizes, shapes, thicknesses

Rigid Flex Board Construction

Layer	Material	Thickness	Function
Coverlay (top)	Polyimide film	0.5 mil	Protects flex copper from damage
Flex copper layers	Rolled annealed (RA) copper	0.5-1 oz	Signal traces in flex areas
Polyimide core	Flexible base material	1-2 mil per layer	Insulation between flex layers
Flex copper layers	Rolled annealed (RA) copper	0.5-1 oz	Signal traces in flex areas
Coverlay (bottom)	Polyimide film	0.5 mil	Protects flex copper
FR4 rigid sections (added on rigid areas only)	FR4 + prepreg + copper	0.4-2.4 mm	Component mounting, additional routing

Key point: The flexible polyimide core runs continuously through the entire board. FR4 is selectively added only where rigidity is needed.

Common Rigid Flex Board Configurations

Configuration	Rigid Sections	Flex Sections	Typical Application
Single flex tail	2	1	Laptop hinge, clam shell device
Multiple tails	1 + multiple satellites	2+	Medical scope, multi-sensor array
Z-fold	3	2	Foldable phone, stackable modules
Parallel sections	3+	2+	Multi-panel display
Book-fold	2	1 (foldable)	Portable instrument, foldable device

Rigid Flex Board Fabrication – Capabilities

Parameter	Our Capability
Rigid sections – layer count	2 to 12 layers per section
Flex sections – layer count	1 to 4 layers
Number of rigid sections	2 to 8+ sections
Rigid thickness per section	0.6mm to 2.4mm (can vary by section)
Flex thickness	0.1mm to 0.4mm
Copper – rigid sections	1 oz to 6 oz
Copper – flex sections	0.5 oz or 1 oz RA (rolled annealed)
Min trace/spacing (rigid)	4 mil / 4 mil
Min trace/spacing (flex)	4 mil / 4 mil
Min drill size	0.20mm mechanical
Bend radius (static)	Minimum 10x flex thickness
Bend radius (dynamic)	Minimum 30x flex thickness
Surface finish	ENIG (preferred), HASL, OSP, Immersion Silver
Stiffeners	FR4, polyimide, or metal
EMI shielding	Silver ink, copper layer, or shielding film

Design Guidelines for Rigid Flex Board Fabrication

Design Element	Recommendation	Why
Bend radius	≥10x flex thickness (static), ≥30x (dynamic)	Prevents copper fatigue and cracking
Flex length	Allow extra length for bending	Prevents stress on rigid sections
Flex width	Consistent width – no sharp corners	Reduces stress concentration
Trace routing in flex	Perpendicular to bend axis	Minimizes stress on traces
Via placement	No vias in bend areas	Vias crack under flex stress
Copper weight in flex	0.5 oz preferred (1 oz max)	Thinner copper bends better
Copper type in flex	Rolled annealed (RA) only	RA copper withstands bending
Coverlay	Use coverlay (not solder mask) on flex	Coverlay flexes, solder mask cracks
Component placement	Rigid sections only	Flex too thin for heavy components
Stiffeners	Add under connectors on flex tails	Prevents flex damage during mating

Rigid Flex Board vs. Alternatives

Feature	Rigid PCB + Cable	Flexible PCB Only	Rigid Flex Board
Heavy component support	Excellent	Poor (needs stiffeners)	Excellent
Bendability	None (cable bends)	Excellent (entire board)	Excellent (flex sections)
Connectors needed	Yes (2-4)	Fewer	None
Space efficiency	Good	Excellent	Very good
Weight	Heavy	Light	Light
Reliability	Moderate	Good	Excellent
Assembly complexity	High	Low	Low
Total system cost	Often higher	Moderate	Often lower

Applications for Rigid Flex Board Fabrication

Industry	Application	Why Rigid Flex is Ideal
Aerospace	Avionics, satellite electronics	Vibration resistance, weight reduction
Medical	Endoscopes, patient monitors, hearing aids	No connector failure, small size
Wearables	Smartwatches, fitness bands, AR/VR glasses	Fits curved enclosures, low weight
Industrial	Robotics, CNC controllers, sensors	Dynamic flexing, rugged environment
Automotive	Camera modules, sensors, infotainment	Vibration resistance, tight spaces
Consumer	Laptops, tablets, foldable phones, cameras	Hinge connection, space efficiency
Military	Portable radios, ruggedized equipment	High reliability, shock/vibration resistance

Why Choose Our Rigid Flex Board Fabrication?

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
Free DFM review	Rigid flex specific – at no charge

Rigid Flex Board Fabrication – Process

Step	What Happens	Time (prototype)
1. Submit Gerber files	Upload your design	Minutes
2. Free DFM review	We verify bend radius, vias, stackup	24-48 hours
3. Stackup validation	Confirm rigid and flex layer arrangement	Included
4. Receive quotation	Detailed pricing	24-48 hours
5. First article (optional)	5-20 pieces for validation	10-15 days
6. Production	Built to your specifications	12-20 days
7. 100% electrical test	Including flex continuity	Included
8. Secure shipping	DHL/FedEx/UPS to your door	1-5 days

Order Process for Rigid Flex Board

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

New to rigid flex boards? Start with a prototype (5-10 pieces) to validate your design before mass production. We provide free DFM review to catch issues early.

Q1: What is the difference between a rigid flex board and a rigid PCB?

Feature	Rigid PCB	Rigid Flex Board
Material	FR4 only	FR4 + polyimide
Bendability	None – breaks if bent	Yes – flex sections bend
Multiple rigid sections	Requires separate boards + connectors	One board with flex connectors
3D packaging	Difficult	Easy – folds to fit
Connectors between sections	Required	None

Rigid flex board is the choice when you need multiple rigid sections connected without connectors.

Q2: Can I put components on the flex sections of a rigid flex board?

A: Not recommended – but possible with stiffeners.

Component Type	On Flex (no stiffener)	On Flex (with stiffener)
Small passives (0402, 0603)	Yes (careful)	Yes
Small ICs (SOIC, QFN)	No (flex too thin)	Yes
Connectors	No (damages flex)	Yes
BGA, large ICs	No	No

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

Q3: What is the minimum bend radius for a rigid flex board?

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: Can rigid flex boards replace cable assemblies?

A: Yes – that is one of the primary applications.

Traditional Approach	Rigid Flex Board Approach
Rigid PCB #1	Rigid section #1
Connector #1	No connector
Cable / Wire harness	Integrated flex section
Connector #2	No connector
Rigid PCB #2	Rigid section #2

Single board, continuous traces, no connectors, no cables.

Q5: Is rigid flex board fabrication more expensive than rigid PCB fabrication?

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

Cost Component	Rigid + Cable + Rigid	Rigid Flex Board
PCB fabrication	Lower (2 boards)	Higher (1 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
Field failures	Connector failures possible	No connector failures

For many applications, rigid flex board total system cost is lower despite higher per-board cost.

Q6: What copper type should I use for flex sections on a rigid flex board?

A: Rolled Annealed (RA) copper – standard for all rigid flex boards.

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

We use RA copper as standard for all flex sections.

Q7: What is the typical lead time for rigid flex board fabrication?

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 (10-12 days for simple configurations) – contact us for urgent requirements.

Q8: Do you offer stiffeners on rigid flex boards?

A: Yes – stiffeners add rigidity to flex sections for component or connector support.

Stiffener Type	Thickness	Best For
FR4 stiffener	0.1-0.5mm	ZIF connectors, general 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 rigid flex boards?

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 rigid flex designs, we strongly recommend starting with a prototype (5-10 pieces).

Q10: How do I get started with rigid flex board fabrication?

A: Recommended workflow:

Design rigid sections – place all heavy components (processor, battery, connectors)
Design flex sections – connect rigid sections, ensure adequate flex length for bending
Verify bend radius – flex length must accommodate required fold angle
Avoid vias in flex areas
Use RA copper for flex layers
Use coverlay (not solder mask) on flex sections
Send Gerber files to us for DFM review
Order prototype (5-10 pieces) – validate folding and electrical continuity
Test and approve before mass production

We offer free DFM review for rigid flex board 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.

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