Electronics are shrinking, getting lighter, and expected to perform flawlessly in demanding environments. From medical wearables to industrial sensors and consumer devices, the push for smaller and smarter products is fueling new approaches in manufacturing. One breakthrough is roll-to-roll (RTR)...
From the palm of your hand, smartphones have revolutionized how we connect, work, and navigate the world. But behind the sleek glass and metal casing lies a key technology that makes their compact, high-performance design possible: flexible printed circuits (FPCs).At PICA Manufacturing Solutions, we specialize in engineering...
Modern products rarely fit neatly into a single interconnect category. Tight packaging, moving joints, long cable runs, heat-dense modules, and fast digital links often coexist in the same device. That’s where Hybrid PCB Assemblies shine. By combining rigid, flexible, flat flexible...
In the expanding world of medical devices, and wearables, the demand for biocompatible substrates in flex and rigid PCBs has never been greater. As electronic systems move closer to and even into the human body, designers and manufacturers must ensure that every...
As electronic devices become faster and more compact, susceptibility to electromagnetic interference (EMI) increases. Effective EMI control is not only about material selection—it requires a comprehensive strategy involving grounding, enclosure-level shielding, and cable shielding. In this post, we’ll explore best practices for each of...
Designing a flexible PCB is not just about taking the layout practices from rigid boards and applying them to a bendable surface. Trace routing, the way copper pathways are arranged, has a direct impact on electrical performance, mechanical reliability, and long-term manufacturability....
As electronic devices become more compact and powerful, managing heat effectively is critical to ensuring performance, reliability, and long product lifespans. Excessive heat can cause component failures, signal degradation, and even safety hazards. Whether working with rigid PCBs, flexible circuits,...
IntroductionAs electronics evolve to become thinner, lighter, and more complex, Flex Printed Circuit Boards (FPCBs) have emerged as a key solution. But building these flexible circuits into reliable assemblies requires precision and deep expertise. In this post, we walk through the Flex Printed Circuit Board Assembly (FPCBA)...
As electronic devices shrink and signal speeds increase, one design requirement becomes mission-critical: controlled impedance. This is especially true in flexible circuits—where mechanical and electrical performance must coexist in tight, dynamic spaces.At PICA Manufacturing Solutions, we help engineers design and build flexible and
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...
