Flex PCB for Drones

Flex PCB for drones is becoming a game-changer, driving the next wave of innovation from micro aerial photography to industrial inspections. As the global drone market continues to expand, the push for lighter, more integrated designs is stronger than ever. Unlike traditional rigid PCBs, flex PCBs are reshaping drone design by offering greater flexibility, reducing weight, and enabling high-density integration. This article explores how flex PCB technology is breaking past old limitations and unlocking new levels of drone performance.

What is Flex PCB for Drones?

Flex PCB uses polyimide or polyester substrates and realizes circuit wiring on flexible substrates through photolithography. It has three core characteristics:

• Ultra-thin structure: The thickness can be compressed to 0.1mm, which is more than 70% lighter than hard PCB.

• Dynamic bending: The bending resistance exceeds 100,000 times.

• Three-dimensional wiring: Supports±180°bending installation and the space utilization rate is increased by 300%.

Core Application of Flex PCB in Drones (UAVs)

Flight control system neural network

The flight control system of drones requires efficient data transmission and reliable connection. Flex PCB ensures stable operation of the flight control system with its high-density wiring and anti-vibration capabilities.

• The gyroscope/accelerometer module uses multi-layer flex PCB interconnection, and the signal transmission delay is reduced to 0.8ns.

• 360° folded wiring realizes the miniaturization packaging of IMU (inertial measurement unit).

High-definition image transmission hub.

High-definition cameras and gimbal control modules require high-quality signal transmission. A flexible circuit board provides a low signal loss and high-speed transmission solution to make drone images clear and stable.

• 4K camera module is directly connected to the image transmission chip through flex PCB, and the impedance fluctuation is controlled within ±5%

• DJI Mavic 3 uses a rigid-flex circuit board, which reduces the weight by 23g.

Power system energy artery

• Flex PCB wiring between brushless motor and ESC, temperature resistance up to 150℃.

• The battery management system of drones requires light and bend-resistant lines. Flex PCB can reduce wiring space, reduce power consumption, and improve endurance.

Folding arm dynamic joint

• A spiral flex PCB design is applied to the hinge part, and the bending radius is ≤3mm.

• Increase the folding life to 5000 cycles (DJI laboratory data).

Intelligent sensor network

• The millimeter wave radar array uses embedded flexible PCB, and the wiring density reaches 40 lines/cm².

• The cost of distributed temperature/pressure sensor networking is reduced by 65%. ​​

Advantages of drone flex PCB

Lightweight design

Reduce the overall weight of the drone and improve endurance.

Durable and vibration-resistant 

Adapt to the high-speed flight of drones in complex environments.

High-density wiring 

Meet the needs of miniaturized and high-performance electronic systems.

Stable signal

Low electromagnetic interference, ensuring lossless data transmission.

Conclusion

With the rapid development of the drone (UAVs) market, flex PCB technology is also constantly being optimized. In the future, new solutions such as high-frequency flex PCB and high-speed flex PCB, Rigid-Flex PCB, and low-power flex PCB will further enhance the intelligence and performance of drones.

On the road to lighter, stronger, and smarter evolution of drones, the flexible circuit board has been upgraded from an auxiliary component to a core enabling technology. Choosing a flex PCB supplier with IATF 16949 certification will directly determine the competitiveness of the product in terms of endurance, reliability, and cost control. Contact our engineering team now to obtain customized drone flex PCB solutions and seize the new blue ocean of low-altitude economy.