Extra-Long Flexible Circuits (FPC)

Extra-long Flex Printed Circuits (FPC)

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Extra-Long Flex Printed Circuits (FPC) for High-Reach Applications

Flexible Printed Circuits Engineered for Length, Precision & High-Performance

When your design demands a flex circuit that spans meters in length instead of inches, standard FPC suppliers won’t cut it. PICA specializes in extra-long flexible printed circuits — up to 3,000 mm (118 in) — with top tier dimensional accuracy, flatness, minimal shrinkage and tailored process methods (panel-based or roll-to-roll).

Why Choose Extra-Long Flex Printed Circuits?

Exceptional Length Capability – Supports spans up to 3,000 mm (118 in) for genomics, automation, medical imaging, security scanning and more.
Dimensional Precision & Flatness – Tight tolerances on thickness (min 0.13 mm, tolerance ±0.03 mm), alignment (±0.1 mm) and profile (±1 mm to ±5 mm depending on length).
Manufacturing Flexibility – Both panel-based and roll-to-roll (RTR) processing paths allow optimization for multi-layer precision or high-volume run lengths.
Support for Demanding Use Cases – Ideal for applications where the flex circuit spans long distances, integrates with moving parts, or eliminates multiple connectors/harnesses.
Engineering-Driven DFM & Manufacturability – Early collaboration to manage stiffeners (SUS), finger-designs, backing, tolerance build-up and shrinkage issues for extra-long formats.

Extra-Long Flex Printed Circuits Capabilities – Highlights

Lengths up to 3,000 mm (118 inches).
Standard widths of 250 mm and 500 mm, thickness down to 0.13 mm (± 0.03 mm).
Alignment tolerance of ±0.1 mm, profile tolerance between ±1 mm to ±5 mm depending on length.
Two primary manufacturing methods:
• Panel-Based Processing — precision multi-layer, tighter tolerances.
• Roll-to-Roll (RTR) Processing — high-volume single- or double-layer flexible circuits.
Design guidance for extra-long builds: use of SUS stiffeners for dimensional stability; stiffener edges placed ≥ 0.5 mm from critical features; finger-designs with solid or no copper-backing; tapered / recessed plug-and-pull fingers by 0.2 mm.
Ideal for medical, automation, security surveillance, wearables and industrial systems requiring long interconnect spans and high-flex reliability.

Global Design & Manufacturing Support

PICA partners with your engineers early to define stack-ups, tolerances, stiffeners and shrink-control strategies for extra-long flex circuits. We guide process selection (panel or roll-to-roll), support prototyping through volume builds, and ensure manufacturable, stable results across extreme lengths.

Benefits of Extra-Long Flex Printed Circuits

Extendable Reach
Long-span flex circuits eliminate multiple connectors and harnesses by providing a continuous circuit from point A to B — reducing assembly complexity and failure points.

Precision Across Length
Tight control of thickness, alignment and profile means a board that remains flat, reliable and dimensionally sound even at extreme lengths.

Volume-Optimised Manufacturing
With both panel and RTR methods, you can select the most cost-effective, high-throughput approach for your length, layer and volume requirements.

Reliability in Challenging Use Cases
Whether in medical imaging gantries, onboard security scanners, long-reach robotics or wearable/industrial systems, certified extra-long flex circuits stand up to real-world stresses.

Design Freedom & Product Simplification
Long flex circuits free you from mini-harnessing, allow creative form factors, reduce interconnect transitions and simplify your bill-of-materials (BOM).

Markets We Serve with Extra-Long Flex Printed Circuits

Industrial Automation & Robotics
Deploying long-reach sensors, scanning arms, conveyor systems and robotic modules benefits from extra-long, single-piece flex circuits instead of complex wire bundles.

Medical Imaging & Diagnostics
Ultrasound probes, imaging tables, long-span patient monitors, diagnostics equipment — require precise, long flex paths with tight flatness and minimal shrinkage.

Security, Surveillance & Scanning Systems
X-ray tunnels, body scanners, baggage inspection, surveillance systems employ flex circuits that span the entire device, in ultra-long formats with high reliability.

Wearables, Transportation & Mobile Systems
Flexible assemblies in vehicles, e-mobility, large-format displays or foldable platforms that need extended flex lengths and efficient interconnects.

Consumer/Display & Large-Format Electronics
Displays, foldables, large span interconnects (e.g., rollable displays, extended sensor arrays) require flex circuits built for length, flatness and precision.

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