Learn how to design professional KiCad flex PCB projects using only open-source tools. This comprehensive guide will walk you through everything you need to know about creating flexible printed circuit boards with KiCad, from basic concepts to advanced techniques.

Understanding Flex PCBs

Flexible printed circuit boards (flex PCBs) represent a revolutionary advancement in electronics design, offering capabilities that traditional rigid boards simply cannot match. These bendable, lightweight circuit platforms are transforming industries from consumer electronics to medical devices.

What is a Flexible PCB?

A flexible PCB is a circuit board manufactured on a flexible substrate, typically polyimide, that allows the board to bend, fold, and conform to three-dimensional shapes. Unlike their rigid counterparts, flex PCBs can be twisted, curved, and even dynamically flexed during operation, opening up new possibilities for electronic design.

Common Applications for Flex Circuits

Flex PCB technology has found its way into numerous applications:

• Consumer electronics: Smartphones, tablets, and wearables
• Medical devices: Hearing aids, pacemakers, and implantable sensors
• Automotive electronics: Dashboard displays and control systems
• Aerospace: Satellite components and lightweight avionics
• Industrial equipment: Rotating and moving assemblies

Differences Between Flex, Rigid, and Rigid-Flex PCBs

Understanding the distinctions between these PCB types is crucial for effective design:

• Flex PCBs: Completely flexible, can bend in multiple directions, ideal for dynamic applications
• Rigid PCBs: Traditional solid circuit boards with no flexibility
• Rigid-Flex PCBs: Hybrid designs combining rigid sections for components with flexible interconnections

Key Challenges in Flex PCB Design

Designing flex PCBs comes with unique considerations:

• Managing bend radii to prevent copper trace fractures
• Accounting for material elongation and compression during flexing
• Ensuring reliable connections between components and the flexible substrate
• Controlling impedance across bending areas
• Optimizing layer stackups for both flexibility and functionality

Why Choose KiCad for Flex PCB Design?

KiCad flex PCB design is now easier than ever thanks to recent software advancements in this powerful open-source EDA (Electronic Design Automation) suite. More designers are turning to KiCad for their flexible circuit needs.

The Open-Source Advantage

KiCad’s open-source nature provides several distinct benefits:

• Zero licensing costs: Completely free for personal and commercial use
• Full feature set: Access to professional-grade PCB design capabilities
• Transparency: Direct visibility into how the software functions
• Customizability: Ability to modify the software for specific requirements

Cost Savings vs. Proprietary Tools

When compared to commercial alternatives like Altium Designer or Cadence Allegro, KiCad offers substantial savings:

• No recurring subscription fees (saving thousands annually)
• No seat licensing restrictions for team environments
• Free updates and new feature releases
• Reduced training costs through accessible documentation

Community Support and Available Plugins

The vibrant KiCad community provides valuable resources:

• Extensive user forums and discussion boards
• Specialized plugins for flex PCB design workflows
• Shared footprint and symbol libraries
• Collaborative troubleshooting for complex design challenges

Latest KiCad Features Supporting Flex PCB Workflows

Recent KiCad versions have introduced capabilities specifically beneficial for flex PCB design:

• Enhanced zone handling for complex outlines
• Improved DRC (Design Rule Checking) for flexible regions
• Better visualization of bend areas
• More sophisticated layer stack management
• Advanced teardrops and rounded tracks for improved flex durability

Preparing for Your Flex PCB Project

Proper preparation is essential before starting your KiCad flex PCB project.

Initial Project Planning

Begin with thorough planning:

• Define clear mechanical and electrical requirements
• Identify fixed and flexible regions
• Establish bend requirements (static vs. dynamic)
• Document environmental considerations (temperature range, humidity)
• Determine manufacturing constraints

Mechanical Considerations

Pay special attention to these critical mechanical factors:

• Bend radius: Typically 6-10 times the material thickness for reliable operation
• Stack-up complexity: Single-sided, double-sided, or multi-layer configurations
• Neutral bend axis: Positioning critical traces at the neutral bend axis
• Stiffener locations: Strategic placement for component mounting areas

Choosing the Right Substrate

Substrate selection impacts performance:

• Polyimide (Kapton): Most common, excellent flexibility and temperature resistance
• PET (Polyethylene terephthalate): Lower cost alternative for less demanding applications
• LCP (Liquid Crystal Polymer): Superior electrical properties for high-frequency designs
• Modified FR4: For semi-flexible applications with limited bend requirements

Best Practices Before Starting Layout

Establish these fundamentals before beginning layout:

• Create detailed mechanical drawings including bend areas
• Define layer stackup and material specifications
• Set up appropriate design rules for flex circuits
• Prepare component placement strategy for flex/rigid zones
• Document flexing requirements (one-time vs. dynamic)

Setting Up KiCad for Flex PCB Design

Properly configuring KiCad is crucial for successful flex PCB projects.

Installing and Updating KiCad

Ensure you’re using the latest version:

• Download KiCad from the official website (kicad.org)
• Check for updates regularly as flex PCB support continues to improve
• Consider nightly builds for cutting-edge features if you’re comfortable with beta software

Creating a New Project for Flex PCB

Start with a well-organized project structure:

• Create a dedicated project folder
• Set up hierarchical sheets if using complex designs
• Establish proper version control practices
• Configure project-specific libraries for specialized flex components

Layer Stack-up Configuration for Flex Circuits

Optimize your layer configuration:

• Typically use fewer layers than rigid boards (1-2 layers is common)
• Place signal layers at the neutral bend axis when possible
• Consider asymmetrical stackups carefully (can cause bias toward bending in one direction)
• Document stack-up details for fabrication

Recommended Design Rules and DRC Settings

Configure these specialized design rules:

• Trace width: Usually wider than rigid PCBs (minimum 0.15mm recommended)
• Spacing: Greater clearances in flex areas (minimum 0.15mm)
• Via usage: Limited or eliminated in flex regions
• Pad sizes: Larger pads with teardrops for better adhesion

Using Zones, Keepouts, and Controlled Impedance Traces

Implement these advanced features:

• Define no-route zones in bend areas
• Create keepouts for areas requiring specific clearances
• Design controlled impedance traces perpendicular to bend lines
• Use hatched ground planes in flex regions instead of solid copper

Read more about:

• Flex PCB Assembly
• 2 Layer Flex PCB
• 4 Layer Flex PCB
• Single Layer Flex

Pro Tip: How to set up your first KiCad flex PCB project correctly

For best results, start by creating custom design rule profiles specifically for flexible circuits. Set up separate rules for rigid areas and flexible zones, with more conservative constraints for the latter. This dual-rule approach helps prevent common flex PCB failures.

Schematic Capture for Flex PCBs

Effective schematic design is the foundation of successful flex PCBs.

Tips for Modular, Flexible Designs

Create schematics with flexibility in mind:

• Organize circuits by functional blocks
• Use hierarchical sheets for complex designs
• Consider physical layout requirements during schematic design
• Group components that will reside on the same flex section

Net Naming Conventions for Complex Circuits

Implement clear naming standards:

• Use descriptive prefixes for different flex sections
• Label critical signals that cross bend areas
• Document high-speed signals requiring impedance control
• Create naming hierarchies for complex multi-board designs

Best Practices for Schematic Clarity

Enhance readability and maintainability:

• Add detailed annotations about flex requirements
• Include mechanical constraints as drawing notes
• Use color coding for different flex regions
• Document expected bend locations and requirements

PCB Layout: Flex-Specific Strategies

The layout phase requires specialized techniques for successful flex PCB design.

Setting Board Outlines and Flexible Zones

Define your flex PCB geometry:

• Create precise board outlines following mechanical requirements
• Designate flex zones with clear boundary markings
• Add bend indicators for fabrication guidance
• Include alignment features for assembly

Designing for Bending and Dynamic Flexing

Accommodate movement in your design:

• Place traces perpendicular to bend lines when possible
• Use curved traces rather than right angles in flex areas
• Implement teardrop pad transitions for improved durability
• Stagger traces across layers to prevent stress concentration

Trace Width and Spacing Recommendations

Follow these guidelines for reliable flex circuits:

• Use wider traces in flex regions (minimum 0.15mm recommended)
• Maintain greater spacing between traces in bend areas
• Avoid abrupt width transitions in flexible sections
• Consider using rounded corners for all traces

Via and Pad Design Considerations

Optimize these critical elements:

• Eliminate vias in flex regions when possible
• Use larger pads with teardrops for component mounting
• Consider anchoring techniques for SMT components
• Implement stress relief patterns around pad connections

Adding Stiffeners and Support Regions

Incorporate mechanical reinforcements:

• Design stiffener areas for component mounting
• Add support for connectors and high-stress regions
• Include proper transitions between stiff and flexible areas
• Document stiffener materials and thicknesses

Visualizing Bending Areas in KiCad

Enhance your design visibility:

• Use separate layers to mark bend lines
• Create 3D models showing the expected flex configuration
• Add bend radius indicators to fabrication drawings
• Include notes about maximum bend angles

Optimizing Copper Pours for Flexibility

Modify standard pour techniques:

• Use hatched ground planes instead of solid copper in flex areas
• Implement spokes or mesh patterns for improved flexibility
• Add strain relief cutouts in copper areas crossing bend regions
• Maintain symmetrical copper distribution when possible

Advanced Techniques

Take your KiCad flex PCB designs to the next level with these specialized approaches.

Designing Rigid-Flex Circuits in KiCad

Create hybrid designs:

• Define distinct rigid and flexible zones
• Implement proper transitions between regions
• Use specialized stackups for different areas
• Document fabrication requirements precisely

Multi-Board Projects and Panelization Tips

Efficiently produce multiple designs:

• Create panelized layouts for cost-effective manufacturing
• Include test coupons for quality verification
• Add tooling holes and fiducial markers
• Design break-away tabs or mouse bites for separation

Impedance Control for High-Speed Flex PCBs

Maintain signal integrity:

• Calculate impedance requirements considering substrate properties
• Implement coplanar waveguides for critical signals
• Maintain reference planes for controlled impedance traces
• Document impedance requirements for fabrication

Tips for Creating Flexible Antennas and Sensors

Explore specialized applications:

• Design flexible antennas with precise impedance matching
• Create distributed sensor arrays utilizing the flex substrate
• Implement strain gauges integrated into the flex circuit
• Develop wearable interfaces with ergonomic considerations

Fabrication and Export

Prepare your KiCad flex PCB designs for successful manufacturing.

Preparing Gerber Files for Flex PCB Manufacturers

Generate comprehensive fabrication data:

• Export complete Gerber file sets (including coverlay layers)
• Create detailed fabrication notes
• Include stack-up specifications and material requirements
• Add bend line indicators and flex zone markings

Specific Fabrication Notes for Flex Boards

Provide clear manufacturing guidance:

• Specify coverlay materials and thicknesses
• Document stiffener requirements and locations
• Include detailed information on bend requirements
• Add notes about dynamic vs. static flex applications

Recommended Fab Houses for Flex PCBs

Consider these manufacturing partners:

• PCBWay
• JLCPCB
• FPCBA
• All Flex
• MKS Flex

Using KiCad’s Fabrication Outputs Efficiently

Maximize manufacturing success:

• Generate comprehensive drill files
• Export detailed assembly drawings
• Create pick-and-place files for automated assembly
• Provide 3D models showing the intended flex configuration

Testing and Validation

Ensure your flex PCB designs perform as expected.

Visual Inspections Specific to Flex PCBs

Look for these critical factors:

• Examine bend areas for defects or stress indicators
• Check layer alignment in multi-layer designs
• Inspect coverlay adhesion and edge coverage
• Verify stiffener placement and attachment

Flex Cycle Testing Tips

Validate durability:

• Implement systematic bend testing procedures
• Document cycle count expectations
• Test under environmental extremes when applicable
• Monitor for early failure indicators

Common Issues and Prevention

Address these frequent problems proactively:

• Trace cracking in bend areas
• Delamination of copper from substrate
• Component or solder joint failure during flexing
• Coverlay separation or adhesion problems

Resources and Further Learning

Continue developing your KiCad flex PCB design skills.

Useful KiCad Plugins and Scripts

Enhance your workflow with these tools:

• KiCad StepUp for improved mechanical integration
• InteractiveHtmlBom for assembly documentation
• KiCost for bill of materials management
• RF-tools-KiCad for impedance calculations

Links to Official Documentation

Access authoritative information:

• KiCad official documentation (docs.kicad.org)
• IPC-2223 Sectional Design Standard for Flexible PCBs
• Material manufacturer design guidelines
• Fabrication house design rules

Recommended Forums and Communities

Connect with fellow designers:

• KiCad.info Forums
• Reddit’s r/KiCad and r/PrintedCircuitBoard
• EEVblog Electronics Forum
• PCB Design Stack Exchange

Conclusion

With practice, anyone can master KiCad flex PCB design and create professional flexible circuits. The combination of powerful open-source tools and a supportive community makes KiCad an excellent choice for flex PCB development. As flexible electronics continue to grow in importance across industries, the skills you develop using KiCad for flex design will become increasingly valuable.

By following the guidelines in this article, you’ll be well-equipped to tackle flex PCB projects of varying complexity. Remember that successful flex PCB design requires attention to both electrical and mechanical considerations, with particular focus on materials, bend requirements, and manufacturing constraints.

We encourage you to experiment with KiCad’s flex PCB capabilities and share your experiences with the open-source community. Each project contributes to the collective knowledge base and helps advance the state of flexible circuit design for everyone.

Frequently Asked Questions

What minimum trace width should I use for flex PCB designs in KiCad?

For flexible circuits, it’s recommended to use trace widths of at least 0.15mm (6 mil) in bend areas. This provides better durability during flexing compared to narrower traces. For static areas, standard trace widths can be used, but always verify your manufacturer’s capabilities first.

Can KiCad handle rigid-flex PCB designs?

Yes, KiCad can handle rigid-flex PCB designs through careful layer stack-up configuration and zone management. The process requires defining different design rules for rigid and flex sections, creating appropriate board outlines, and adding detailed fabrication notes. Recent versions of KiCad have improved support for these hybrid designs.

How do I indicate bend lines in KiCad for flex PCB manufacturing?

The best practice is to create dedicated layers for bend lines using KiCad’s user layers. These should be included in your fabrication outputs with clear annotations about bend direction, radius, and whether the bend is dynamic or static. Adding dimensioned drawings showing the bend specifications is also highly recommended.

What’s the main difference between designing a regular PCB and a flex PCB in KiCad?

The main differences involve mechanical considerations, trace routing approaches, and layer stack-up. Flex PCBs require careful attention to bend areas, typically use fewer layers, need wider traces in flex regions, and often include stiffeners for component mounting. Design rules must be more conservative, and copper pours should use hatched patterns rather than solid fills in bend areas.

How can I test my flex PCB design before manufacturing?

Before committing to fabrication, use KiCad’s 3D viewer to visualize the design, verify all DRC rules are properly configured for flex circuits, perform manual reviews of bend areas, and consider creating simplified mechanical prototypes using paper or plastic films to validate the folding concept. For critical designs, some manufacturers offer prototype services with faster turnarounds specifically for testing flex circuit concepts.