Customizing flexible PCB is not an easy task. It requires detailed information and a certain process. This article will provide you with a detailed introduction to the information required for customizing flex PCBs, as well as guidelines for prototyping and mass production.
What information is needed to customize flex PCB?
1. Gerber file
Gerber file is the standard output format for PCB design. It has info about each layer of the PCB, like the circuit layer, solder mask layer, silk screen layer, and so on. It’s the key file that manufacturers use to make PCBs. Ensuring the accuracy and completeness of Gerber files is the first step in customizing flexible printed circuit boards.
2. Number of PCB layers and structure
Flexible PCBs can be one-layer, two-layer, or multi-layer structures. You gotta clearly let the manufacturer know how many layers the flex PCB has and what materials are needed for each layer. Common flexible PCB materials include PI and PET.
3. Circuit board size and shape
The size and shape of the flex PCB directly affect its application scenario. You need to provide the overall dimensions, thickness requirements, and any special shape design (such as cutouts, slots, etc.) of the circuit board.
4. Electrical performance requirements
Including electrical performance requirements such as impedance control, signal integrity, and voltage resistance of the printed circuit board. These requirements will affect the design and material selection of the PCB.
5. Surface treatment process
There are lots of choices for surface treatment processes for flexible PCB, like immersion gold/ tin, OSP, etc. Different surface finished processes can affect the soldering performance and durability of the circuit board.
6. Special requirements
If you’ve got special requirements, like high-frequency signal processing, high-temperature resistance, corrosion resistance, and so on, you need to let the manufacturer know in advance. That way, they can pick the right materials and processes.
7. BOM (Bill of Materials)
If your flex PCB needs to be assembled with components, you need to provide a BOM. The BOM should contain information such as the model, quantity, and package of the components.
8. Test requirements
Clarify the test requirements of the circuit board, such as electrical testing, functional testing, environmental testing, etc. Test requirements will affect the production cycle and cost.
Flex Plus has a lot of experience in making and testing flex PCBs for many years, We provide a range of testing solutions that are made to fit the special needs of flexible PCBs.
Flex PCB proofing process
1. Demand communication
Before proofing, you need to communicate with the manufacturer in detail to ensure that both parties agree on the design, materials, and processes of the flexible printed circuit.
2. Design review
The manufacturer will conduct a design review on the Gerber files and other materials you provide to check whether there are design defects or process problems. If there are any problems, the manufacturer will make modification suggestions.
3. Sample production
After confirming that the design is correct, the manufacturer will start making samples. The proofing cycle of flex PCBs is usually 5-10 working days, depending on the complexity of the circuit board.
4. Sample testing
After the sample is made, the manufacturer will conduct electrical and functional tests on the sample to ensure that it meets the design requirements. You can also test the sample yourself to verify its performance.
5. Feedback and modification
If the sample test results do not meet expectations, you need to communicate with the manufacturer and make modification suggestions. The manufacturer will make adjustments based on the feedback and remake the sample.
Flex PCB mass production process
1. Confirm mass production documents
After the proofing is passed, you need to confirm the final mass production documents, including Gerber files, BOM tables, test requirements, etc. Make sure all documents are accurate to avoid problems in mass production.
2. Material procurement
The manufacturer will buy the corresponding materials based on your needs, such as base material, cover films, adhesives, etc. The quality and consistency of materials are really important for the performance of the circuit board.
3. Manufacturing
The mass production of flex PCBs includes multiple processes, such as line etching, lamination, drilling, electroplating, surface treatment, etc. Every process needs strict quality control to make sure the circuit board is reliable.
4. Quality inspection
During the production process, the manufacturer will do a bunch of quality checks on the circuit board. This includes electrical testing, appearance inspection, dimensional measurement, etc. Only flexible circuit boards that pass these inspections can move on to the next step.
5. Packaging and delivery
After all the production processes are done, the manufacturer will pack the circuit board and ship it out according to what you want. The packaging method should ensure that the circuit board won’t damaged during transport.
Things to note when choosing a flex PCB manufacturer
1. Experience and qualifications
Choose manufacturers with rich experience and good qualifications to ensure that they can handle complex flex PCB design and production needs.
2. Equipment and technology
Advanced equipment and technology are the guarantee for producing high-quality flex PCBs. Ensure that the manufacturer has modern production lines and testing equipment.
3. Quality control system
The quality control system of the manufacturer has a direct impact on the reliability of the circuit board. Choose a manufacturer that has passed ISO9001 and other quality management system certifications.
4. After-sales service
Good after-sales service can help you solve problems encountered during production and make sure the project goes smoothly.
Summary
Customizing flex PCB is a really complicated process, you need to give detailed info and work closely with the manufacturer. From making samples to mass production, every step needs strict quality control to make sure the final product works as expected. If you choose a flex PCB manufacturer with experience and advanced technology, you can get high-quality flex PCBs that suit your application needs.
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