Flex PCB Manufacturer
Rapid Prototype & Volume Flex PCB Fabrication Services
As a leading China flex PCB supplier, we specialize in high-quality flex circuit manufacturing—from rapid-turn prototyping to full-volume flexible PCB fabrication. Upload your Gerber files now for a fast, reliable quote.
What is Flex PCB Manufacturing?
Flex PCB manufacturing refers to the process of designing and fabricating flexible printed circuit boards (FPCs) — electronic interconnects made from flexible substrates like polyimide or polyester.
Unlike rigid PCBs, Flex PCBs can bend, fold, or twist without breaking, making them ideal for compact, dynamic, or curved electronic applications.
Applications
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Wearable Devices
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Automotive Electronics
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Medical Equipment
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Aerospace and Military Systems
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Consumer Electronics (Foldable Phones, Cameras, etc.)
Key Characteristics
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Flexible Substrate Materials
Typically polyimide or PET, offering excellent thermal stability and flexibility.
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Compact Design
Enables 3D routing, reducing space and weight in electronic devices.
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Durability
High resistance to vibration and movement over time, making them suitable for dynamic environments.
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Customization
Easily tailored to meet the electrical and mechanical requirements of specific applications.
Manufacturing Process
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Design & Stack-Up Planning
Optimizing the circuit layout for bendability, impedance, and signal integrity.
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Photolithography & Etching
Creating copper traces on the flexible base material.
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Lamination & Coverlay Application
Protecting the circuit with flexible cover films or solder masks.
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Drilling & Plating
Forming vias and applying copper through-holes for interlayer connections.
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Testing & Quality Assurance
Electrical testing, visual inspection, and reliability checks (IPC standards compliant).
Our Core Advantages
Premium Materials Only
We use high-grade polyimide and RA copper to ensure excellent flexibility, heat resistance, and long-term reliability. All materials meet RoHS and IPC Class 3 standards.
Advanced Fabrication Process
From single-layer to HDI rigid-flex, our manufacturing process ensures tight tolerances, controlled impedance, and high-density trace routing.
Engineering Support Included
Our in-house engineers offer DFM guidance, Gerber reviews, and stack-up optimization — helping you reduce revisions and shorten your time to market.
Certified Quality Control
We follow ISO 9001 and IPC-6013 guidelines with 100% E-testing, AOI, and reliability checks for every production run — prototypes and mass orders alike.
Fast, Flexible Delivery
We support quick-turn prototyping (as fast as 48 hours) and scalable mass production with flexible batch sizes and global logistics.
Trusted Across Industries
Our Flex PCBs are used in medical, automotive, consumer, aerospace, and industrial products — anywhere performance and space savings are critical.
Capabilities
| Capability | Parameter |
|---|---|
| PCB Type | Flexible PCB |
| Quality Grade | Standard IPC 2 |
| Material |
PI PET |
| Number of Layers |
1 Layer 2 Layers 4 Layers 6 Layers 8 Layers |
| Max PCB Size | 1 Layer: 4000mm x 240mm 2 Layers: 800mm x 240mm Multi-layers: 350mm x 240mm |
| Board Size Tolerance (Outline) | ±0.1mm |
| Soldering Pad Diameter | ≥0.3mm |
| Quality Grade | Standard IPC 2 |
| Lead Time | 5-7 Days |
| Coverlay | Yellow, White, Black, None |
| Coverlay Opening Size | ≥0.6mm x 0.6mm |
| Min Spacing Colverlay to Soldering Pad | ≥0.15mm |
| Soldermask Color | Green and Others |
| Soldermask Bridge |
Green: ≥0.1mm Others: ≥0.15mm |
| Minimum Character Width (Legend) | ≥0.7mm |
| Minimum Character Height (Legend) | ≥0.8mm |
| Min Spacing from Silkscreen to Soldering | ≥0.2mm |
| Surface Finish |
ENIG OSP Immersion Tin Chemical Silver |
| Impedance Control |
Single-ended 50Ω Differential Pairs100Ω Tolerance ±10% |
| Stiffener Material |
PI FR-4 Aluminum Steel |
| Edge Rail Width | ≥10mm |
Product Showcase
Design and Manufacturability
Manufacturing Process Overview
Material Preparation & Cutting
The process begins with high-performance flexible base materials, typically polyimide films laminated with copper foil. These sheets are precisely cut to panel size, ready for photolithography and circuit patterning.
Drilling (Via and Hole Creation)
Next, microvias and through-holes are created to connect different layers or accommodate component pins. This is done using laser drilling for microvias or mechanical drilling for larger holes. Precision and cleanliness are critical to ensure high-quality interconnects.
Proper via wall quality ensures better plating adhesion and long-term reliability.
Circuit Pattern Imaging
The flexible copper-clad material is coated with photoresist and exposed to UV light through a circuit mask (phototool). This defines the required circuit pattern. The unexposed resist is then removed, revealing the copper to be etched away.
Copper Etching
In this step, chemical etching removes unwanted copper, leaving only the intended circuitry. High-resolution etching is essential to achieve fine line/space and controlled impedance required in modern flex circuits.
Layer Lamination (for Multilayer Flex or Rigid-Flex)
For multilayer designs, individual flex layers are aligned and laminated together under controlled temperature and pressure. Adhesive layers and polyimide films are used to form a unified structure. Rigid-flex PCBs include rigid sections laminated into the stack-up during this phase.
Coverlay Application or Solder Mask
To protect the circuits, a polyimide coverlay or liquid solder mask is applied. Coverlay is more flexible and preferred for dynamic flex applications. Openings are created at pads, vias, or connector areas for soldering or component assembly.
Surface Finish Application
Surface finishes like ENIG (Electroless Nickel Immersion Gold), OSP, or HASL are applied to exposed copper pads. This step improves solderability, oxidation resistance, and contact performance.
Component Soldering (Optional for Assembly Services)
If Flex PCB assembly is requested, components are placed and soldered using reflow or hand soldering techniques. SMT-compatible flex PCBs are typically assembled in array panels for ease of handling.
Electrical Testing & Final Inspection
Every board undergoes electrical continuity and isolation testing to verify open/short circuits. Visual inspections and AOI (Automated Optical Inspection) ensure trace accuracy and pad quality. Additional tests may include X-ray, dimensional checks, and bend-cycle reliability tests.
Final Cutting, Packaging & Shipping
Finished PCBs are laser-cut or routed into final shape and packaged in ESD-safe materials. Custom labeling, serialization, and documentation are included per customer request.
FAQ
The recommended minimum bend radius depends on whether the flex area is static or dynamic:
- Static Flexing: Minimum radius = 6× the board thickness
- Dynamic Flexing: Minimum radius = 12× or more of the board thickness
Using rolled annealed (RA) copper improves bendability and extends flex life.
Flex PCBs are primarily made from polyimide (PI) or polyester (PET) substrates with copper foil layers. We also use adhesiveless laminates for high-reliability applications. Coverlays, stiffeners (FR4 or stainless steel), and surface finishes (ENIG, OSP) are added depending on the design.
Lead times depend on complexity and quantity:
- Prototype Flex PCBs: 3–7 business days
- Production Runs: 7–20 business days
Expedited options are available for urgent projects — contact us for a custom quote.
Yes. We offer full Rigid-Flex PCB manufacturing, including HDI and multilayer designs. Our process supports complex 3D assemblies and ensures precise layer registration and bend reliability.
We offer a range of surface finishes to meet different electrical and soldering requirements:
- ENIG (Electroless Nickel Immersion Gold) – best for fine-pitch and wire bonding
- OSP (Organic Solderability Preservative) – cost-effective, RoHS compliant
- Immersion Silver / Tin, Lead-Free HASL, and others available upon request
- Flex PCBs use flexible base materials and are designed to bend, fold, or twist during use.
- Rigid PCBs are built on FR4 substrates and are not designed for movement.
Flex PCBs save space, reduce weight, and improve durability in dynamic environments.
Absolutely. Our engineering team offers free DFM reviews, helping you optimize your design for manufacturability, cost efficiency, and long-term reliability. Upload your Gerber files, and we’ll evaluate them before production begins.
Yes. All our Flex PCBs are RoHS-compliant and manufactured to IPC-6013 and IPC-A-600/610 Class 2 or Class 3 standards, depending on application needs. Certifications and test reports are available upon request.
To provide an accurate and fast quote, please include:
- Gerber files (RS-274X format preferred)
- Bill of Materials (BOM) if assembly is needed
- Stack-up or layer information
- Quantities and delivery timeline
- Special requirements (e.g., stiffeners, impedance control, finish type)
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