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Why Do Electronics Need Semi Rigid PCB ?

The physical construction of printed circuit boards has changed drastically over the
years, not just because of how they look. Photolithography is a process that uses
ultraviolet light to etch the pattern on the surface of silicon wafers. We can only do
this by using a specific combination of chemicals, making it expensive and
challenging to create large-scale PCBs at scale. Keeping their size small
allows electronic components like semi rigid PCBs to move through water and air
without impedance or damage easily.

Electronics are becoming increasingly small and powerful. Yes, they are even
miniaturizing batteries and using less power. And technology continues to change the
way we live as well as work. However, there is a concern that we can no longer trust
electronics without a PCB. But what is a PCB? A PCB or Printed Circuit
Board stands for the electronic circuit board. It can build circuits in gadgets such
as smartphones, watches, airplanes, and cars, among other things. We can see it as the
brain of a device from which we can connect all its components. The PCB is best for
being rigid and gives precisely what’s needed to build gadgets in a uniform and stable
manner.

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Table of Contents

Introduction

The good thing about this circular layout is that we can use the internal structure of
the PCB to build other components like LCDs and speakers. It makes it easier
for electronic device manufacturers to create products for electronic users. So, with
the development and improvement of bendable circuit boards, there’s no more room
for other devices. The belief is that these devices are relatively inexpensive compared
to older gadgets and much simpler to use. It’s now becoming popular among people.
This is because electronics manufacturing can become more budget-friendly
when making PCBs. We can also use electronics in a wider range of products.
Therefore, electronics companies are now also investing in this field as well.

PCBs are boards with conductive wires in a single layer, the single most crucial
component of your entire device. We will connect all other components to this PCB.
This makes it easier to bring all your components together because of the PCB’s
good layout and design. It is also lightweight and easy to carry. With the use of a PCB,
there is also less problem setting it up.

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PCBs are now being helpful as flexible as well. Electronic manufacturers can now
use the same materials to build bendable circuit board. It also makes it more pliable,
light, and effective for solar cells, batteries, and touch screens, used more often in
newer devices. This will allow users to achieve quicker performance and make
electronics slimmer. Thus, it makes it harder to build with other parts of the gadgets.

What is a semi rigid-Flex PCB?

4 Layer Semi Rigid Flex PCB

A semi rigid-Flex PCB is a flexible PCB with the flexibility and rigidity of a rigid
PCB but has an external look, feel, and function of a rigid PCB. Manufacturers make
the semi-rigid layer of polyethylene terephthalate (PET). It is one of the most
common materials used to build flexible PCBs. PET’s main advantages are its
flexibility, transparency, and toughness. They separate the semi-rigid layer with a
rigid core of either FR4 or Rogers RO4003. FR4 is a glass fiber laminated circuit
board material used for the PCB core. Rogers RO4003 is the other commonly used
PCB in producing semi rigid-Flex PCBs.

There are two types of semi rigid-flex: High Touch and Low Touch

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High Touch Semi Rigid-Flex PCBs

They are flexible, transparent, and challenging. This semi rigid-flex PCB displays the
LCDs and touch screens on most gadgets. It’s made of PET laminated to a rigid
surface using either FR4 or Rogers RO4003. We commonly use it in devices that
require flexibility and lightweight, such as tablets, smartphones, etc.

Low Touch Semi Rigid-Flex PCBs

They are flexible and tough but not transparent. We prepare it the same way as the
High Touch Semi Rigid-Flex, but instead of being transparent, it is black. We use this
type in devices that require less flexibility but durability, such as home appliances,
smartphones, etc.

Both semi flex PCBs are durable and easily soldered together. This is especially with
a low-temperature soldering iron. Solderability is one of the main factors that make
these two durable and long-lasting electronics devices.

Most of the time, we use semi rigid-flex PCBs to build a device with the same
function as a rigid PCB but with a different external look. Therefore, electronics need
semi rigid-flex PCBs for their devices. The use of this kind of PCB will allow
companies to create products and gadgets that we can use for almost any electronic
device.

Advantages of semi rigid-Flex PCBs

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It offers a plethora of advantages. First is the user-friendliness of the PCB. They are
always lightweight, flexible, tough, and pliable, making them a lot easier to carry
around and use. They also have an easy time setting them up on a board because of
their lightweight, thinness, and flexibility. We can also use Flexible PCBs in building
flexible devices such as solar cells, touch screens, and batteries. These are the main
reasons electronics need semi rigid-flex PCBs for their products.

1. Reduced Packaging Size

When using semi rigid-flex PCBs, we will reduce the overall size of the finished
product. Because of its greater versatility in its application. Since they’re flexible,
they will allow electronics manufacturers to reduce their packaging sizes without
compromising on the quality of the final product. When it comes to pricing, it’s
cheaper compared with rigid PCBs while providing the same function. Semi rigid-flex
PCBs are also easier to work with, making them more cost-effective for electronic
manufacturers.

2. Weight Reduction

Semi rigid-flex PCB is best to be lighter compared with rigid PCBs. This is a great
advantage for manufacturers because it allows them to reduce the weight and size of
their products. With less weight and size, the product will also cost less. We can pass
this on to their customers. Also, since it’s more lightweight and flexible, it will make
using the finished products easier.

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3. Improved Flexibility

Flexibility is one of the main benefits of using semi rigid-flex PCBs in products.
Because it’s flexible, we can use it in many different applications. This means that
manufacturers will have more jobs. They can use their products because it’s both
flexible and tough, allowing them to develop devices with a lot more functionality.

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4. Unique Dynamic Stability

By using semi rigid-flex PCBs, devices can have more dynamic stability. This will
allow manufacturers and developers to build many more versatile products that
provide high-quality performance. The PCB can also stretch, which means we can use
it in many different applications.

5. Thin Profile

When it comes to performance, a thin profile is one of the essential things in devices
today. We are building most of them smaller and smaller to fit inside pockets. The
semi rigid-flex PCB is a lot thinner compared with rigid PCBs. This makes it easier to
fit into devices, making them very light. Manufacturers need to keep their products as
light and small as possible to minimize their overall weight. It will lower the cost of
the finished product. We can use it in devices of extremely small size, such as
smartphones, PDAs, digital cameras, etc.

6. Cost-Effectiveness

For electronics manufacturers, semi rigid-flex PCBs are cheaper than the rigid type.
Manufacturers can then pass on this affordable price to end-users. This will make
semi rigid-flex PCBs more popular among buyers because they provide better value
for their money. Semi rigid-flex PCBs will also save them from developing extra
work due to their lightweight and flexibility.

7. Environmental Friendly

Semi rigid-flex PCBs are environment friendly. Because it’s so lightweight, the
products containing semi rigid-flex PCBs will be a lot lighter than other electronic
devices that use rigid PCBs. This means it won’t require a lot of energy to carry,
install and transport them. Also, semi rigid-flex PCBs are flexible, making them

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easier to recycle and repair. This is a great benefit for manufacturers because they can
keep their products clean and pollution-free, helping the environment.

8. Ease of Use

Semi rigid-flex PCBs are a lot easier to use than rigid PCBs. Because they are flexible,
there will be fewer cases of damages. This is because they’re pliable so that they can
easily bend or twist due to accidental drops or bumps. They will also be easier to
install and set up in devices since they can easily fit into tight corners because of their
flexibility and thinness.

9. Impact resistance

Being flexible, semi rigid-flex PCBs are immensely impacting resistant. Even if it
gets stuck, dropped, or bumped, it can still keep its original shape. This is unlike rigid
PCBs, which are more prone to breaking when accidentally damaged. Since we hold
the microchips and components in semi rigid-flex PCBs together by flexible solder
bumps, they can be bendable PCB. The PCB will remain intact even when dropped or
bumped because of this stronghold.

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PCB Design for Flex Electronics Manufacturing

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bendable pcb

Nowadays, flexible PCBs are being used a lot in fabricating flexible electronics. We
use them so much because they can be extremely tiny and thin, making them easy to
incorporate into a wide range of applications. Today there are numerous types of semi
rigid-flex PCBs that you can choose from to meet the needs and requirements of your
application. However, before designing these semi rigid-flex PCBs, you must
consider several factors that will affect the design process, such as:

1. Stiffeners

Stiffeners can provide a lot of strength and support to your semi rigid-flex PCBs. The
stiffeners are usually copper or steel, which you will use to create your design. You
can also use different materials like a crosshatch for the stiffener. It will help
minimize the amount of deflection that occurs when there is an impact on your semi
rigid-flex PCB.

2. Bending Requirements

Before designing your semi rigid-flex PCBs, it’s essential to consider the bending
requirements that are helpful in the industry. The bending requirements can be a great
help when designing your semi rigid-flex PCB. This will allow you to determine how

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the semi rigid-flex PCBs will bend. You can either use an inspection machine for this
or use bend test equipment to check out how much deflection occurs in your design.

3. Mechanical Design

This can be an essential factor you must consider when designing your semi rigid-flex
PCBs. It will help determine how your semi rigid-flex PCBs will bend. If you are
using the conventional mechanical design procedure, you need to design the semi
rigid-flex PCB to bend in a controlled manner. You must also consider the amount of
deflection when bent and how much bending resistance occurs.

4. Solderability

The soldering process is an essential factor that you must consider when designing
your semi rigid-flex PCBs. You will need to make sure that the solderability of your
semi rigid-flex PCBs is not affected in any way. Also, when placing
the components on the board, you must solder them to not interfere with the bending
and flexing of the semi rigid-flex PCB.

5. Electronic Design

This can be an essential step you must take when designing your semi rigid-flex PCBs.
You must make sure that the electronic design for the semi rigid-flex PCBs is
correctly designed and not misdesigned. It will enable you to achieve your desired
result. It would be best to consider how much power the semi rigid-flex PCB
components require and their operating temperature range.

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Design Tips for Rigid-Flex PCBs

Below are a few tips that can help you in the design and creation of rigid-flex PCBs:

There are a lot of factors that will determine which semi rigid-flex PCBs you will
choose. These include the level of flexibility, compatibility, material, and finish. The
best way is to determine the application you will use to determine what you need.

1. Evade Pads & Vias at the Bend Zones

The semi rigid-flex PCBs will be more vulnerable to damage if they have excessively
large and deep via holes. A good tip is to avoid these areas as much as possible in the

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design of semi rigid-flex PCBs. This will ensure that there are no excessive cuts or
holes. It will also help improve the bond strength on their microchips and components.
This prevents them from violation when bending the semi rigid-flex PCB and making
it weak.

2. Make Use of Glass Passives

There are a lot of advantages that we can derive when using glass passives when
designing semi rigid-flex PCBs. This is because it is an excellent insulator. It will also
help protect the semi rigid-flex PCB from damage when accidentally dropped or
bumped. There are a lot of advantages that we can gain from using glass passives in
semi rigid-flex PCBs. These include:

It helps to keep the semi rigid-flex PCB cool even when used in devices with a
high-power demand. This allows the microchips and components to remain stable.
Also, it will enable them to be more flexible, reliable, and durable.

It prevents the semi rigid-flex PCB from bending too much when accidentally
impacted or damaged.

3. Avoid Putting Too Many Connectors

It is best to leave a minimum number of connectors on semi rigid-flex boards

with passive components. This will help reduce their weight and improve their
flexibility and ease of installation. It would be best to place the connectors in areas
where the board can easily access the flexing. This will avoid the need to solder them
at a future date, allowing you to have more flexibility with the design.

Also, it would be best if you placed your connectors in a position where they will not
interfere with the bending of the boards.

4. Use the Hatched Polygon when it comes to Copper Planes

If you are using copper pads for the semi rigid-flex PCB design, it is best to place
them on a very large and broad EPP surface. This will help to improve their
solderability when soldering. This will increase the bond strength and help ensure no
cuts in the semi rigid-flex PCB during bending.

5. Ensure Empty Regions are full with Unwanted Copper Traces

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If you are using semi rigid-flex PCBs in mobile and consumer electronics, the need
for small passives may affect the board’s overall weight. In this case, it is best to fill
up all empty spaces with additional copper traces and vias. So, there will be a
minimum amount of space for the semi rigid-flex PCB, which will give it a more
stable structure and make it easier to bend.

6. Use Oblique Angle for Connectors

The use of oblique angles is an excellent way to reduce the resistance by half. This is
because they are not perfectly perpendicular, so they will avoid selling them later.
After designing your semi rigid-flex PCB, you can now design the rigid parts
using Altium Designer. When designing the rigid parts, you must make sure they fit
with your semi rigid-flex PCB.

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Types of Flex Electronics PCBs

bendable circuit board

Most companies manufacture all PCBs to be flexible. To state this differently, they
engineer the PCBs to withstand certain levels of bending and twisting. They do not
design the boards for extreme flexibility or extreme rigidity. The classification

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depends on the end-use of your PCB. Besides its primary use, one can engineer a flex
PCB to fold or roll.

In general, flex PCBs classification includes:

1. Class 1

These are single-sided boards that are either plain or may contain special layers. They
can bend just slightly, but we cannot roll them.

2. Class 2

These are double-sided boards with a rigid core surrounded by a thin layer of copper
and laminate layers on both sides. Generally, we design this PCB for bending in one
specific plane, like bending around the corners of a box, for example. We can roll
flexible PCBs under this category but not folded because the rigid core bends when
rolled.

3. class 3

We refer to multilayer flexible PCBs with special layers as “flip-chip” PCBs. These
single-sided boards have one rigid layer and a flexible laminate layer on the other side.
They can bend straight or roll but not fold.

4. class 4

We refer to specialized flex PCBs such as cards, backplane, and customized designs
as “flexible” PCBs. They can bend in multiple directions to fit many applications like
flip-chip, saddle, and half-layers

5. class 5 and 6

These are flexible laminate PCBs that are “half sheets” or “double-sided.” They
contain rigid and flexible layers processed together. The degree of bending is greatly
restricted and can bend in only one direction so that the maximum bending radius is
about 8 mm.

6. class 7, 8, 9

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These are special types of flex PCBs designed for specific applications like
drones, military aircraft, and automotive electronics. Most manufacturers design them
to withstand very high bending or twisting, and they do not intend to use them as
flexible PCBs.

Flexible PCBs require special attention when designing rigid components. There are
two reasons for this:

(1) The components like connectors can easily bend out of shape,

(2) Most connectors, pins, vias, etc., have thin walls that can easily break or bent
during the design process.

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Applications for need semi rigid Flex PCB

There are many applications where companies use semi rigid PCBs to fit in space
constraints and be very flexible. These include automotive electronics, medical
devices, wearable electronics, and cell phones. Most of these use the flip-chip method
to create the individually designed semi rigid board.

To manufacture a semi rigid PCB flex, the PCB component manufacturer must follow
some steps like:

1. Making a small custom board

2. Making this small custom flexible PCB component

3. Mating these two together

In this way, we can have a nonflexible (rigid) part in semi rigid (flexible) PCB.

Below is a detailed diagram of semi rigid PCB process.

We make all semi rigid PCBs of three parts: solid core, laminate, and laminate on
both sides. The laminated sheet only provides the lay-flat feature. They can make
these components from FR4 or FR5 material by adding several layers of copper to the
board. This makes the board stiffer and more resilient to bending. We make the core
of the semi rigid flex PCB using a rigid material like epoxy, glass-reinforced
thermoplastics, glass-filled nylon, or metal-filled nylon.

Semi Rigid flex PCBs are so versatile that we can use them in different automotive
electronics, medical devices, wearable electronics, and many others. They can also be
easily processed on a standard manufacturing line or a design service provider and are
significantly cost-effective when the time to market.

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Flexible PCBs are essential in various applications such as automotive

electronics, medical electronics, wearables, and many others.

They can also be easily processed on a standard manufacturing line or a design

service provider and are significantly cost-effective when the time to market.

Conclusion

Though flexible PCBs are helpful in almost every electronic device, they are still not
perfect. This is because semi flex PCBs will surely be better versions of both the rigid
and flexible PCBs in the future and thus more widely used. Since electronics are
becoming more powerful, less expensive, and futuristic, allowing them to become
more common for a wider range of products, there will be no doubt that the
electronics industry will use semi rigid-flex PCBs. It seems like they are here to stay.
So, with the development of semi rigid-flex PCBs, there is no doubt that electronic
devices will become more powerful and better.

Related Posts:

1. Flipchip BGA Vs. Intels BGA Vs. Fujitsus TBGA -The Future of
Semi-Custom Design for High Quality and Affordable Manufacturing

2. What is 6 Layer Rigid-Flex PCB?

3. How To Plan Stackup For Rigid Flex PCB

4. Comparison between Flexible vs. Rigid: How to Differentiate?

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