PICA Manufacturing Solutions specializes in providing Extra Long Flex Printed Circuitry (FPC) with lengths up to 3000mm (118 inches), positioning us among the few suppliers capable of manufacturing boards at this extensive scale. Our Extra Long FPC products offer precise dimensional accuracy, reliable flatness, and minimal shrinkage, meeting stringent requirements across various industries. Utilizing both panel-based and roll-to-roll (RTR) processing methods, we deliver tailored solutions that align with specific customer applications, design stack-ups, and production volumes. Our rigorous quality standards and technical expertise ensure high-performance products suitable for demanding environments.
Manufacturing Methods
PICA leverages advanced manufacturing methods suited to customer-specific requirements:
Panel-Based Processing: Ideal for precision and multi-layer requirements.
Roll-to-Roll (RTR) Processing: Suitable for high-volume, single- or double-layer circuits.
We select the most effective method based on your application’s needs.
Process Capabilities
Maximum Length: Up to 3000mm
Standard Widths: 250mm and 500mm
Thickness: Minimum 0.13mm, tolerance ±0.03mm
Alignment Tolerance: ±0.1mm
Profile Tolerances: ±1mm to ±5mm depending on length
Key Length Considerations
Max exposure window: 2.2 meters for irregular shapes
Step-and-repeat designs: Suitable for RTR production
Optimal Design Recommendations
Use SUS stiffeners for improved dimensional stability
Position stiffener edges at least 0.5mm from critical features
Finger designs: Solid copper backing or no copper backing
Tapered or recessed plug-and-pull fingers by 0.2mm
Applications for Extra Long FPC
Industrial and automation
Medical and healthcare
Security and surveillance
Why Choose PICA for Extra Long FPC?
PICA combines advanced technology, skilled expertise, and rigorous quality controls to deliver reliable Extra Long FPC solutions. We proactively engage in Design for Manufacturability (DFM) to ensure efficient production and top-quality results.
For detailed process capabilities and technical specifications, please fill out the contact form and let us know about your project and questions.
Choosing the Right Manufacturing Method for Extra-Long Flexible Circuits
FPC (Flexible Printed Circuit) manufacturing has evolved significantly, with both panel-based and roll-to-roll (RTR) processing methods widely used. Each method...
Understanding Copper Limits & Bend Radius in Flex PCBs
Whether you're designing for a high-durability dynamic application or a compact static installation, every detail matters—from copper type and thickness...
Understanding Flexible Printed Circuit (FPC) Cost Drivers
Flexible Printed Circuits (FPCs) are essential components in modern electronics, enabling lightweight, compact, and high-performance designs. However, they come...
Common Mistakes Made by PCB Designers When Designing Flexible Circuits (FPCs)
Flexible Printed Circuits (FPCs) are widely used due to their lightweight, flexible, and compact nature, making them ideal for...
Ultra-Thin Flexible Circuits: Overcoming Challenges in Dielectric Substrate
In Part 1, we explored the challenges of manufacturing ultra-thin flexible circuits with a focus on the conductive layers, highlighting...
Building Ultra-Thin Flexible Circuits: Part 1 – Conductor
One of our key customers approached PICA with the challenge of manufacturing ultra-thin flexible circuits. A critical component of this...
Adhesiveless Technologies for Flexible Circuits: Unlocking Next-Generation Performance
In the world of flexible electronics, the shift from traditional flexible copper-clad laminates (FCCLs) to adhesiveless materials represents a significant...
Compliance: Ensuring Safety and Performance in Flexible Printed Circuit Manufacturing
When developing and manufacturing flexible printed circuits (FPCs), adhering to industry standards ensures reliability, safety, and performance. Two pivotal standards...
