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Flexible circuits are built to bend—but only when designed and tested to handle real-world mechanical demands. Whether your product is a wearable device, medical catheter, or automotive sensor, the reliability of a flex circuit under repeated bending, twisting, or flexing is critical to its success.At
As electronic devices evolve to become smaller, smarter, and more power-efficient, engineers are under increasing pressure to maximize performance within minimal space. One innovative solution gaining traction is the use of embedded passive components—resistors, capacitors, and inductors that are built directly into the layers of a flexible printed circuit...
As devices shrink and performance demands grow, engineers are turning to High-Density Interconnect (HDI) technology to pack more function into less space. Whether you're working on a compact sensor, a multi-layer RF module, or a dense wearable board, HDI and fine-line etching open up new possibilities—if you...
In the world of flexible electronics, polyimide films like Kapton® (a DuPont trademark) are a foundational material. Used in everything from flex circuits and medical sensors to MEMS and microfluidic systems, Kapton’s thermal stability and dielectric properties make it ideal—but in many applications, selective removal or patterning...
Rigid-flex PCBs combine the best of both worlds—the durability of rigid boards and the versatility of flexible circuits—into a single integrated solution. They’re ideal for compact, high-reliability applications where connectors and wiring harnesses would add too much bulk or risk.But rigid-flex design isn’t just about stacking rigid and flex...
Designing flexible circuits isn’t just about choosing the right materials, it’s about understanding how all the pieces come together under real-world demands. That’s why we created the PICA Flex Sample Kit, a hands-on tool that lets engineers explore different flex stack-ups, materials, and design strategies.Tangible Innovation You...
Why AOI and Quality Control Matter in PCB and Flex Circuit Manufacturing When it comes to PCB and flex circuit manufacturing, even the most well-designed layout can fail if the build process introduces errors. That’s why quality control—and specifically Automated Optical Inspection (AOI)—is a critical part of every reliable fabrication process. As...
From Flexible Circuits to Flexible ThinkingOur journey began in 1995 through a strategic partnership with M-Flex, providing engineering and sales support for flexible circuits. Over the next three decades, PICA evolved from a flex specialist into a global electronics manufacturing force—expanding our reach, capabilities, and commitment to our customers at...
This blog is an excerpt from the white paper Guide to PCB & FPC Manufacturing Processes: Subtractive, Semi-Additive & Additive Techniques. Request the full white paper here. As PCBs and flex circuits evolve to support smaller devices, denser routing, and higher performance, engineers are turning to more advanced copper...
How to Protect Your Flex Circuits: Strain Relief and Tear Resistance StrategiesFlexible circuits—such as FFCs, FPCs, and rigid-flex assemblies—offer unparalleled design freedom in compact and dynamic electronic applications. However, their inherent flexibility makes them susceptible to mechanical stresses that can lead to failures like tearing, delamination, or conductor fatigue. Implementing...
When working with high-voltage circuits, design priorities shift. While many PCBs focus on high-speed signaling, impedance control, or component density, high-voltage designs prioritize safety, insulation, and spacing. Whether you're developing an industrial power controller, EV subsystem, or medical device, successful high-voltage PCB design demands a clear understanding of creepage, clearance,...
There was a time when business success was measured by how much a company could do in-house. From raw material procurement to delivery, fully vertically integrated corporations—think Ford or General Electric—dominated. The logic was simple: control every step, minimize risk. But that model no longer fits today’s fast-changing environment. The most...
When designing flexible circuits, especially those with irregular shapes, it’s easy to overlook how layout decisions impact manufacturing efficiency. But how your parts are nested within a panel directly affects both material waste and cost. That’s why it’s important to consider panel optimization early in the design process—not just during...
In multilayer PCB fabrication, what connects copper layers together isn’t just glue—it’s carefully engineered dielectric materials that control signal integrity, insulation, and mechanical performance. Among these, prepreg plays a critical role, serving as both an adhesive and an electrical insulator between copper layers. Whether you’re working on high-speed digital signals, RF layouts,...
For engineers balancing performance, flexibility, and cost, Flat Flexible Cables (FFC) remain one of the most efficient interconnect solutions in electronics today. Their simple structure, adaptability, and low manufacturing cost make them ideal for countless applications—from consumer electronics to industrial controls, smart home, industrial equipment, vehicles, electric...
In PCB manufacturing, solder mask isn’t just about making a board look green—it’s a functional layer that protects copper traces, prevents solder bridging, and improves overall assembly yield. But not all solder masks are created equal. From rigid PCBs to flexible circuits and high-density designs, the type of solder mask used—and...
Printed Circuit Board (PCB) manufacturing involves precise processes, not just in design and component assembly but also in how the final boards are separated from their manufacturing panels. At PICA Manufacturing Solutions, we use various depaneling techniques to ensure efficiency, accuracy, and cost-effectiveness. The three primary methods—V-scoring, routing, and die...
Conductive Inks and Their Role in Flexible and Printed ElectronicsAs electronics continue to evolve beyond rigid, boxy enclosures, the materials and processes used to build them are changing too. Conductive inks are a key enabler of this shift, offering engineers the ability to print circuitry directly onto thin, flexible, and...
Selecting the right base material for a PCB is never a simple choice. The properties of the substrate affect everything—from thermal stability to dielectric performance, mechanical strength, and manufacturing compatibility. Four standard materials dominate PCB fabrication: FR-2, FR-4, CEM-1, and CEM-3. While all of them provide insulation and structural integrity,...
FPC (Flexible Printed Circuit) manufacturing has evolved significantly, with both panel-based and roll-to-roll (RTR) processing methods widely used. Each method has its own advantages, limitations, and specific applications, particularly when manufacturing extra-long flex circuits. Below is a comparison highlighting capabilities specifically relevant to producing extra-long FPCs depending on application needs,...
