RAYPCB / Flexible circuits
Double-Sided Flexible PCB Manufacturing
Two copper layers, with the interconnection and connector details settled early.
Share your drawings, quantities and mechanical requirements for an engineering-reviewed quote. You can contact us directly without completing the optional tools.
Double-Sided Flexible PCB — design decisions
A double-sided flex PCB adds a second routing layer and may use plated interconnections between the two faces. It can provide extra routing capacity or a reference conductor, but its thickness, pad openings and reinforcement still need to suit the mechanical installation.
| RFQ detail | What to provide | Why it changes the job |
|---|---|---|
| Interconnections | Hole chart, pad diameters and finished hole requirements | Defines plating and the finished electrical connection. |
| Copper usage | Routing, return conductors and any copper balancing requirements | A second layer is not automatically a continuous impedance reference plane. |
| Coverlay | Openings around pads and connector lands | Opening geometry and registration affect assembly access. |
| Stiffeners | Drawing with local thickness and connector tolerances | Adhesive and flex thickness contribute to the finished insertion dimension. |
For a worked thickness review, use the two-layer stackup and connector design guide. For fabrication, send the layer artwork, drill data and reinforcement drawing together.
Quote a two-sided circuit with its openings and holes defined
| Manufacturing input | Why it changes the build |
|---|---|
| Finished copper on both sides | Changes etching, flexibility and local thickness. |
| Plated holes and their locations | Defines interconnection processing; bend-zone holes need specific review. |
| Coverlay artwork | Controls exposed lands and the protected bend area. |
| Stiffener and adhesive drawing | Defines local support and connector thickness. |
| Panel outline and contacts | Affects handling, assembly and the delivered format. |
This page covers procurement and fabrication of the two-copper-layer circuit. For a layer-by-layer thickness calculation and connector fit, use the two-layer flex design example. Do not use a connector’s nominal thickness as the unreinforced bend-section thickness.
Relevant construction examples
Prepare the two-layer fabrication drawing
State whether copper thickness values refer to starting foil or finished copper. Specify the final construction rather than expecting the fabricator to infer it from a connector photograph. The bending area and the plated-hole area may have different design priorities; mark the mechanical zones clearly.
If two layers cannot carry the required routing, compare four-layer flex construction. If components are included, review flex assembly tooling and support before finalizing the panel.
Material selection starts with the actual laminate, copper and coverlay grades. Refer to DuPont’s laminate portfolio and the supplier drawing for each selected grade. Kapton and Pyralux are not interchangeable names for every flexible circuit material.
Flex design & project planning
Check bend-region thickness and the local connector stack separately. Enter the actual supplier values; do not count stiffeners as part of a flexible bend.
Flexible PCB Design Workbench
Optional bare-flex budget
Choose the construction independently from the design check. This is an early budget scenario; it does not price a validated stackup.
Flexible PCB Budget Estimator
Prepare the next engineering review
Send the available files even if some decisions remain open. Mark the points where you need advice.
- Gerber or agreed fabrication data, outline drawing and drill data where applicable.
- Layer stackup, material grades, finished thickness and tolerances.
- Bend zones, installed radius, motion duty, coverlay openings and reinforcement drawing.
- Connector requirements, order quantities and requested delivery.
Download calculator results if you want to include them. Contact inputs are not automatically filled from these tools.
Practical questions
What is the first decision for this construction?
Resolve two-layer holes and coverlay before treating the layer count as a complete specification. Include the mechanical drawing and identify any unknowns.
Does the design tool approve the bend radius?
No. It checks the entered geometry and planning assumptions; it does not predict fatigue life or release the construction for manufacture.
Is the displayed budget an exact quote?
No. The model is uncalibrated. Unsupported or complex constructions need manual review. Send the files for an exact quotation without completing the calculator if you prefer.