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GESP Technology

15+Years Devoted to PCB Solutions & Manufacturing

Flex PCB

Flex PCB

What is Flex PCB

Flexible circuits (also variously referred to around the globe as flex circuits, flexible printed circuit boards, flex print, Flex-circuits) are members of electronic and interconnection family. They consist of a thin insulating polymer film having conductive circuit patterns affixed thereto and typically supplied with a thin polymer coating to protect the conductor circuits. The technology has been used for interconnecting electronic devices since the 1950s in one form or another. It is now one of the most important interconnection technologies in use for the manufacture of many of today’s most advanced electronic products.


What are the Advantages of Flexible PCB


Flexible printed circuit boards offer a number of potential benefits including:

Saving Space

Flex PCB design requires only about 10 percent of the space and weight of an ordinary circuit board assembly, offering greater installation and packaging freedom. The inherent flexibility also permits tighter bend capabilities.

• Maximum Reliability.

A flexible printed circuit board requires fewer interconnects, which in turn requires fewer contact crimps, connectors, and solder joints. Simply put, a flexible PCB board does not contain as many potential sources for failure, which enhances their reliability.

• Enhanced PCB Capabilities.

The flexible printed circuits boards are compatible with virtually any type of connector or component and work well with options such as ZIP connectors. They also perform extremely well in extreme temperatures and offer superior resistance to radiation and chemicals.

• Cost Savings.

Cost-saving advantages of Flexible PCBs include reduced material and packaging demands, lower parts replacement costs and assembly errors that could result in the need for repairs.


benefits of using multilayer flex pcb design


These benefits make flex PCBs ideally fit for a wide range of applications in industries such as Military, Transportation, Medical, Consumer Electronics, Automotive, Aerospace, Communications, and Industrial.

Miniaturization, Lightweight-Choose Flex PCB

Generally, flexible circuitry is the go-to solution for manufacturers who need:

1.Wiring solutions that fit where rigid boards cannot.

2.Thin, lightweight products that are nonetheless durable.

3.Miniaturized versions of existing technologies.

4.Three-dimensional packaging geometry.

  1. A low number of device interconnects.

6.Shock and vibration resistance.

These benefits point to flexible circuitry options as an ideal solution for mobile consumer electronics. Enterprising circuit board amateurs who take apart their smartphones or laptop computers will find a wealth of flexible circuitry inside any modern device on the market.

In the case of mobile devices, the use of rigid circuitry would result in a device too large, too heavy, and too fragile to conveniently carry around. This was the case with the Osborne I, the first fully powered mobile computer, which weighed in at an intimidating 24.5 pounds.

Size and weight reduction represent only one half of the flexible circuit story, however. They are also ideal for high temperature and high-density applications.

Flex PCB Fabrication Applications

High Temperature and High-Density Applications

In many cases, flex circuits are made of polyimide or a similar polymer. This material dissipates heat better than most rigid circuit board materials. For this reason, flexible circuits can be placed in inconvenient locations where heat would impact the performance of a rigid circuit board.

Flexible circuit boards can be designed to withstand extreme temperatures – between -200° C and 400° C – which explains why they are so desirable for borehole measurements in the oil and gas industry.

In fact, because of these conditions, and the need for small, unobtrusive devices in most industrial environments, flexible circuits represent the first choice for engineering design in most industrial sensor technologies.

High-temperature resistance comes usually comes with good chemical resistance and excellent resistance to radiation and UV exposure as well. Combined with the ability to control impedances in high-density circuit board designs, flexible circuit designs offer many benefits to manufacturers.

GESP Flexible PCB Capability

Layer Count
Final Thickness
0.002″ – 0.1″ (0.05-2.5mm)
Surface Treatment
Lead-free: ENG Gold; OSP, Immersion silver, Immersion Tin
Max / Min Board Size
Min: 0.2″x0.3″  Max: 20.5″x13″
Min Trace Width
Min Clearance Inner
0.5oz: 4/4mil
1oz: 5/5mil
2oz: 5/7mil
Min Trace Width
Min Clearance Outer
1/3oz-0.5oz: 4/4mil
1oz: 5/5mil
2oz: 5/7mil
Min Hole Ring Inner
0.5oz: 4mil
1oz: 5mil
2oz: 7mil
Copper Thickness
1/3oz – 2oz
Max / Min Insulation Thickness
2mil/0.5mil (50um/12.7um)
Min Hole Size&Tolerance
Min hole: 8mil
Tolerance: PTH±3mil, NPTH±2mil
Min Slot
24mil x 35mil (0.6×0.9mm)
Silkscreen Line Width
Gold Plating
Nickel: 100u” – 200u”
Gold: 1u”-4u”
Immersion Nickel / Gold
Nickel: 100u” – 200u”
Gold: 1u”-5u”
Immersion Silver
Silver: 6u” – 12u”
Film: 8u” – 20u”
Test Voltage
Testing Fixture: 50-300V
Profile Tolerance of Punch
Accurate mould: ±2mil
Ordinary mould: ±4mil
Knife mould: ±8mil
Hand-Cut: ±15mil

Why Not Make All Circuit Boards Flexible?

Flexible circuit boards are certainly useful, but they are not going to replace rigid circuit boards for all applications. Cost efficiency is the main obstacle to implementing an exclusively flexible circuit board design in a consumer product. Rigid circuit boards are less expensive to manufacture and install in a typical automated high-volume fabricating facility.

Typically, the ideal solution for an innovative product is one that incorporates flexible circuitry when necessary and employs solid, reliable rigid circuit boards where possible to keep manufacturing and assembly costs down.

Some manufacturers even use hybrid rigid-flex printed circuit boards expressly for this purpose. This is common in laptop computers and medical devices, where rigid circuit boards can be connected to one other using ribbon-like flexible circuits. These boards can be compounded and designed to meet any number of engineering needs by focusing on the respective strengths of each circuit board base technology.

GESP Technology creates both flexible and printed circuit boards for product manufacturers. Enjoy a consultation with one of our sales reps to find out if your product prototype design is best served by flexible or rigid circuit board types.

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