Rigid Flex Circuit Boards / Rigid Flex PCB
Custom Rigid-Flex Circuit Boards Engineered for Reliability
PICA designs and manufactures rigid-flex printed circuit boards (PCBs) that combine the structural reliability of rigid boards with the design freedom of flexible circuits. These hybrid PCBs streamline complex designs, eliminate bulky connectors, and withstand shock and vibration—making them ideal for compact, high-reliability electronics.
Rigid-flex PCBs are trusted in aerospace, defense, medical, automotive, and consumer electronics, where space is limited and performance is mission-critical. With advanced stack-up options, impedance control, and precision assembly, PICA provides rigid-flex PCB solutions that deliver durability, miniaturization, and electrical stability.
Design for Manufacturability (DFM) Support for Rigid-Flex PCB Designs
Designing rigid-flex circuit boards requires close coordination between mechanical, electrical, and manufacturing requirements. PICA works with customers early in the design phase to optimize layout, stack-up, bend regions, material selection, and assembly planning, helping reduce redesigns, delays, and unnecessary cost.
Our engineering team reviews customer designs and provides feedback on:
- Rigid-to-flex transition areas
- Bend radius and flex region layout
- Layer stack-up and material selection
- Adhesive vs. adhesiveless flex constructions
- Controlled impedance routing for high-speed signals
- Via placement, annular rings, and drill-to-copper clearance
- Stiffener, connector, and component placement
- Coverlay, solder mask, and exposed copper requirements
- Panelization and manufacturing efficiency
- Assembly considerations for SMT and through-hole components
This early DFM collaboration helps improve reliability, reduce manufacturing risk, increase yield, and support a smoother path from prototype to production.
Request a Quote and Download Our Full Rigid Flex Capabilities
Why Choose Rigid-Flex Circuit Boards?
Space-Saving Design – Combines rigid strength and flexible routing in one board.
High Reliability – Fewer connectors reduce failure points in demanding applications.
Durability Under Stress – Superior resistance to bending, vibration, and thermal cycling.
Compact Integration – Ideal for tight enclosures requiring 3D configurations.
Design Flexibility – Supports innovative layouts and high-density interconnects.
Rigid-Flex PCB Capabilities
Technology
- Rigid Sections Up to 40 layers, 0.25 – 8mm (Application Dependent)
- Flex Layers Up to 32 Layers, 0.05 – 0.35mm (Application Dependent)
- Cut-Back/Selective Coverlayer or Soldermask
- Air Gap Constructions (Flexibility)
- Epoxy Fillet Strain Relief
- Impedance Control (TDR Testing & Verification)
- High Frequency Signals
- Resistance Control
- High Power
Materials
- FR4 Min Tg130 .C, 150 .C, 170 .C & 180 .C, Td>335 .C
- Low-Flow Adhesive & No-Flow FR4 Prepreg
- Halogen Free, ROHS & REACH Compliant
- UL 94 V-0 Approved
- Flex Layers: PI – Adhesive: Epoxy Acrylic – Adhesiveless
- Copper: Electrodeposited (ED), Rolled Annealed (RA)
- Shielding: EMI film, Silver (Ag) ink, Copper Plane
Patterns & Holes
- Space & Trace: 50μm (2 mils)
- Copper Thickness Inner: 1/2 – 2oz Outer: 1/3 – 4oz
- 0.15mm (.006”) Drilled Through-Holes
- HDI Capability
- Blind Vias and Buried Vias, 0.076mm (3.0mils) Laser Vias
- Via In Pad, Filled Vias, Stacked Vias
- Resin or Copper Paste Plug Hole dia. ratio: 15:1
- Pattern & Button Plate
- 4+N+4 Max. Stack
Benefits of Rigid-Flex PCBs / Rigid Circuit Boards
Optimized Space Utilization
Ideal for compact or irregular spaces, rigid-flex PCBs enable device miniaturization without sacrificing performance.
Enhanced Reliability
By removing connectors and cables, rigid-flex designs reduce failure points and improve long-term system reliability.
Superior Durability
These boards withstand vibration, shock, and repeated bending, ensuring stable performance in harsh environments.
Weight Reduction
Lightweight flex materials and fewer connectors make them significantly lighter than traditional rigid PCBs.
Design Versatility
Rigid-flex PCBs support complex 3D layouts, bending, and folding, unlocking innovative, space-efficient solutions.
Markets We Serve with Rigid Circuit Boards / Rigid-Flex PCBs
Consumer Electronics:
Powering compact devices like smartphones, tablets, and wearables with lightweight, space-saving designs.
Medical Devices:
Used in pacemakers, hearing aids, implants, and diagnostics where flexibility and reliability are critical.
Automotive:
Built into control modules, lighting, and infotainment systems to withstand vibration, heat, and irregular layouts.
Industrial Equipment:
Trusted in robotics, sensors, and control systems for durability in harsh environments.
Defense & Security:
Essential in satellites, and avionics, combining lightweight efficiency with extreme durability.
PCB, Flex & PCBA Cost Pressures in 2026: What OEMs Need to Watch
Electronics manufacturing is heading into 2026 under pressure from several directions at once. Rising metals costs, laminate and prepreg repricing,...
How to Choose Flex PCB Materials for Bend Reliability, Heat, and Cost
A practical step-by-step method for choosing materials that hold up in bending, assembly, and real environmentsFlex material...
What Auxiliary Materials Are Used in Flex PCBs? Stiffeners, EMI Shielding, Spacers, and Adhesives?
Stiffener, EMI Shielding, Release liners, spacers, marking inks, thermally conductive adhesive films, and PSA selection guidance.When engineers...
Rigid-Flex: The Winning Technology Behind Smart Impact Monitoring Mouthguards
When it comes to sports safety, precision and reliability are non-negotiable. Impact monitoring mouthguards, like those used to measure head...
Biocompatible Substrates for Flex and Rigid PCBs
In the expanding world of medical devices, and wearables, the demand for biocompatible substrates...
How to Design Rigid-Flex PCBs for Reliability: Bend Areas, Stackups, and Interconnects
Rigid-flex PCBs combine the best of both worlds—the durability of rigid boards and the versatility of flexible circuits—into a...
Case Study: Innovating Medical Healthcare Technology with Rigid Flex PCB Design
Customer Overview: The customer in this case study is a leading company in the healthcare technology sector, known for its...
6-Layer ELIC Rigid Flex Printed Circuit Board / Rigid Flex PCB
A 6-Layer ELIC (Every Layer Inter-connect) Rigid Flex Printed Circuit Board / Rigid Flex PCB is an advanced and...
Request Your PICAKit Today
We want you to take a look at what we can produce for you by offering you a PICAKit which includes a variety of flexible pcb, shields, & flat flexible cables.
