Dynamic Flex Circuits | High-Cycle Flexible PCB Solutions

Dynamic Flex

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Dynamic Flex Circuits for High-Cycle Bending

Flexible Circuits Designed for Continuous Motion

Dynamic flex printed circuits are engineered to bend repeatedly—thousands to millions of times—without cracking or drifting out of spec. PICA’s design-driven team optimizes copper grain direction, bend radii, layout, and material stacks to deliver stable, repeatable performance throughout the product lifecycle.

These circuits enable reliable motion in wearables, medical devices, robotics, automotive controls, and foldable electronics where space is tight and durability cannot fail.

Why Choose Dynamic Flex Printed Circuits?

• Proven High-Cycle Durability
Validated for continuous bending in products requiring years of repeated motion.

• Optimized Conductor Strain
Copper thickness, trace orientation, and grain structure are tuned to prevent fatigue.

• High Reliability Without Extra Connectors
Eliminates moving wire harnesses, reducing failures and simplifying assembly.

• Stable Electrical Characteristics Under Motion
Maintains consistent impedance and signal performance while flexing.

• Engineered Bend Regions
Designed to protect pads, vias, and terminations from stress-induced cracking.

Dynamic Flex Capabilities – Highlights

• Designed for 100,000 to 1,000,000+ bend cycles

• RA (Rolled Annealed) copper and ultra-thin foils for extended flex life

• Adhesiveless polyimide for reduced thickness and improved fatigue resistance

• Air-gap and window constructions to minimize stress in bend areas

• Dynamic-focused routing: staggered traces, filleted corners, tear-stop features

• Supports controlled impedance and high-speed designs under motion

• Selective stiffeners, strain relief, and connector reinforcement

• Bend support for 90° and 180° motion systems

Global Design & Manufacturing Support

With engineering in the U.S. and production capabilities in Malaysia, PICA supports rapid prototyping through volume manufacturing of dynamic flex circuits. Our early-stage design collaboration helps prevent fatigue issues before they make it to production, saving time and cost.

Benefits of Dynamic Flex Circuits

High-Cycle Motion Reliability
Dynamic flex circuits survive repeated bending through specialized copper selection, thickness control, and strain-free routing.

Reduced Mechanical Stress
We control strain at critical areas—like pads, vias, and connectors—ensuring fatigue-free durability.

Thin, Lightweight Motion Systems
Eliminate bulky wire harnesses with ultra-light, space-saving flex elements ideal for wearables and compact medical devices.

Cleaner, More Reliable Interconnects
Dynamic flex bridges moving assemblies without connectors, improving reliability and reducing assembly complexity.

Consistent Electrical Performance in Motion
Impedance and electrical values stay stable even during repetitive bending, protecting high-speed signals and sensitive sensors.

Markets We Serve with Dynamic Flex Circuits

Wearables & Consumer Electronics
Hinges, straps, foldable displays, and compact portable electronics benefit from small-radius flexing.

Medical Devices
Miniaturized circuits for patient-monitoring, diagnostic sensors, and body-worn equipment requiring motion reliability.

Automotive & Transportation
Used in rotating displays, steering systems, seat controls, and vibration-heavy environments requiring robust motion tolerance.

Industrial Automation & Robotics
Continuous movement in sensors, actuators, and robotic joints demands highly reliable bend-tolerant circuitry.

Communications & Instrumentation
Dynamic flex enables repositionable sensor heads and sliding mechanisms with stable electrical performance.

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