Rigid Flex PCB – Rigid Flex Circuit Board Manufacturer

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

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Rigid Flex PCB – Rigid Flex Circuit Board Manufacturer

A Rigid Flex PCB (rigid flex circuit board) 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.

As a rigid flex circuit board manufacturer, we specialize in building these hybrid boards to your exact specifications. Whether you need a simple 2-section board for a laptop hinge or a complex multi-section board for a medical device, we deliver high reliability, space-saving designs that eliminate connectors and cables.

If your product needs to fold, fit into a curved enclosure, or survive vibration while holding heavy components, rigid flex PCB is the solution.

What is a Rigid Flex PCB?

Feature	Description
Rigid sections	FR4 material – supports processors, connectors, batteries, large passives
Flex sections	Polyimide (Kapton) – bends, folds, twists
Continuous traces	Copper runs uninterrupted from rigid to flex to rigid
No connectors	Single board replaces rigid PCB + cable + rigid PCB assemblies
Single SKU	One board, one part number, one assembly

Think of it as: Multiple rigid PCBs that are “born connected” by flexible hinges.

Rigid Flex PCB vs. Traditional Assembly

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

Why Choose a Rigid Flex PCB?

Benefit	How Rigid Flex PCB 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 jumps at connectors
Lower assembly cost	One board to place, not multiple boards + cables
Simpler logistics	One SKU instead of 3-5 SKUs

Rigid Flex PCB Construction

Layer	Material	Thickness	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 areas
Polyimide core	Flexible base material	1-2 mil	Insulation between flex layers
Flex copper	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. FR4 is selectively added only where rigidity is needed.

Common Rigid Flex PCB 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

Rigid Flex PCB Manufacturing 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 PCB

Design Element	Recommendation	Why
Bend radius	≥10x flex thickness (static), ≥30x (dynamic)	Prevents copper fatigue
Flex length	Allow extra length for bending	Prevents stress on rigid sections
Flex width	Consistent – no sharp corners	Reduces stress concentration
Trace routing	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

Rigid Flex PCB vs. Alternatives

Feature	Rigid PCB + Cable	Flexible PCB Only	Rigid Flex PCB
Heavy component support	Excellent	Poor	Excellent
Bendability	None (cable bends)	Excellent	Excellent
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 PCB

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
Automotive	Camera modules, sensors, infotainment	Vibration resistance
Consumer	Laptops, tablets, foldable phones	Hinge connection
Military	Portable radios, ruggedized equipment	High reliability

Why Choose Us as Your Rigid Flex Circuit Board Manufacturer?

Feature	What You Get
True rigid flex integration	Continuous traces from rigid through flex to rigid
RA copper standard for flex	Withstands repeated bending
No connectors needed	Eliminate connector failure points
Engineering support	Bend radius analysis, stackup design
Prototype available	Fast turnaround for validation
Volume production	Scalable to your needs
ISO9001 & UL certified	Quality guaranteed
Free DFM review	Rigid flex specific – at no charge

Manufacturing Process for Rigid Flex PCB

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. Receive quotation	Detailed pricing	24-48 hours
4. First article (optional)	5-20 pieces for validation	10-15 days
5. Production	Built to your specifications	12-20 days
6. 100% electrical test	Including flex continuity	Included
7. Secure shipping	DHL/FedEx/UPS	1-5 days

Order Process for Rigid Flex PCB

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 PCB? Start with a prototype (5-10 pieces) to validate your design before mass production.

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

Feature	Flexible PCB (FPC)	Rigid Flex PCB
Construction	Entire board bends	Rigid sections + flex sections
Component support	Limited	Excellent (on rigid sections)
Best for	Simple bendable circuits	Complex systems with heavy components

Rigid flex PCB is the choice when you need to mount heavy components AND bend/fold.

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

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	Yes
Connectors	No	Yes
BGA, large ICs	No	No

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

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

Flex Thickness	Static Bend (one-time)	Dynamic Bend (repeated)
0.1mm (1 layer)	1mm (10x)	3mm (30x)
0.2mm (2 layers)	2mm	6mm
0.3mm (3 layers)	3mm	9mm
0.4mm (4 layers)	4mm	12mm

Rule of thumb: 10x thickness static, 30x thickness dynamic. Tighter bends = higher risk of copper cracking.

Q4: Can rigid flex PCB replace cable assemblies?

A: Yes – that is a primary application.

Traditional Approach	Rigid Flex PCB 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 PCB more expensive than rigid PCB?

A: Per board: Yes. Total system cost: Often lower.

Cost Component	Rigid + Cable	Rigid Flex PCB
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

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

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

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

Q8: Do you offer stiffeners on rigid flex PCB?

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 MOQ for rigid flex PCB?

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 as a customer?

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 PCB 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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Rigid Flex PCB – Rigid Flex Circuit Board Manufacturer