RAYPCB / Flexible circuits
Flexible PCB Manufacturing
Select the layer structure, define how it bends, and send a complete fabrication enquiry.
Share your drawings, quantities and mechanical requirements for an engineering-reviewed quote. You can contact us directly without completing the optional tools.
Flexible PCB construction: select by the job
See how the chosen film, copper, coverlay and support features move through the flex PCB manufacturing process, including an opening-exposure worksheet.
A flexible PCB carries copper circuitry on a flexible dielectric. Its value comes from fitting electrical connections into the product’s mechanical space. A circuit bent once during installation and a circuit that moves repeatedly need different design and qualification decisions.
| Construction | Primary question | Explore |
|---|---|---|
| Single-Sided Flexible PCB | One copper layer for a thin, clearly defined interconnect. | View Single-Sided Flexible PCB Manufacturing |
| Double-Sided Flexible PCB | Two copper layers, with the interconnection and connector details settled early. | View Double-Sided Flexible PCB Manufacturing |
| 4 Layer Flex PCB | Four routing layers require a mechanical stackup as well as an electrical one. | View 4 Layer Flex PCB Manufacturing & Stackup |
| 6 Layer Flexible PCB | Six-layer flex for dense routing—with the mechanical constraints made explicit. | View 6 Layer Flexible PCB Manufacturing |
| Multilayer Flex PCB: Layer & Construction Selection | Choose the required routing and mechanical structure before choosing more layers. | View Multilayer Flex PCB |
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.
Compare rigid and flexible polyimide constructions when a material name leaves the physical structure or thermal evidence unclear.
Need components on the flex? Review flex PCB assembly early enough to plan support tooling and panel handling.
A flex-circuit enquiry begins with the mechanical duty
| Use condition | Provide | Useful next step |
|---|---|---|
| Bent once to install | Flat and installed shape, assembly sequence, local support and bend definition | Check local thickness |
| Repeated motion | Motion path, radius definition, frequency, environment and required life; identify unknowns | Agree the construction and a qualification plan, rather than selecting by layer count alone. |
| Components on the circuit | Placement, stiffeners, panel format, fixture and test access | Plan flex assembly |
A product image can illustrate a board form but cannot establish its material construction or motion life. For your design, agree the regional thicknesses and the conditions under which any bend test is meaningful.
Flexible PCB examples
Original product images from the RAYPCB gallery. Select an image to inspect it. The labels identify the pictured category; they do not certify the specification of your new design.
Keep the moving region and supported region distinct
Keep the bend geometry, connector insertion thickness and component support as separate requirements. A local PI or FR-4 stiffener can reinforce a region without making the entire circuit a rigid-flex PCB. Use rigid-flex construction when the design actually needs rigid circuit sections.
Specify the coverlay openings, bend direction, installed radius, moving length and any repeated-motion requirements. The flex stackup guide supports the thickness discussion. A layer count alone is not a finished stackup.
Use the flex PCB design and bend-zone worksheet to prepare motion, support and routing requirements before releasing the drawing.
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
Agree the inspection evidence your project needs
Define electrical testing, dimensional checks and any required inspection records in the enquiry. A process photograph provides context; your drawing and acceptance criteria define what must be checked.
For repeated-motion designs, agree the mechanical test conditions and acceptance requirements separately. Optical inspection alone does not demonstrate fatigue life.
Use the manufacturing quality checklist to organize the requested evidence.
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.
For a quantity or panel-use comparison, the flex PCB cost worksheet separates whole-panel quantities, expected yield and documented allowances. You can still request a quote directly with the available files.
Practical questions
What is the first decision for this construction?
Resolve motion and installation conditions 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.