Custom Rigid-Flex PCB with 3/3 mil Trace Capability Eliminating Connectors and Cable Interconnects Under IPC-A-600 Standards

Custom Rigid-Flex PCB

Huayihai fabricates custom rigid-flex PCBs that combine rigid FR-4 sections with flexible polyimide circuit layers in one continuous board. Boards are built according to customer Gerber files, allowing three-dimensional assembly without connectors, ribbon cables, or soldered joints between sections.

By integrating flex and rigid regions into a single structure, rigid-flex designs reduce assembly steps, eliminate interconnect failure points, and save space in compact products. Huayihai manufactures rigid-flex PCBs under IPC-A-600 workmanship standards.

Custom Manufacturing Only

We fabricate rigid-flex PCBs according to customer Gerber files and technical specifications. We do not supply ready-made or standard stock boards.

Product Specifications

Key Features

• Rigid and flexible sections in one continuous board

• Eliminates connectors and cable interconnects between boards

• Flexible polyimide layers for dynamic or static bending

• 3/3 mil trace capability on both rigid and flex regions

• Reduces assembly steps and total packaged size

• Manufactured under IPC-A-600 workmanship standards

Manufacturing Highlights

Rigid-flex fabrication requires coordinated lamination of materials with different mechanical behavior. Huayihai manages rigid-flex builds end to end, from bend-zone design review to final inspection of transition areas.

Key fabrication elements include:

• Bend zone and stack-up review of Gerber files

• Sequential lamination of rigid FR-4 and polyimide flex layers

• Controlled transition zones between rigid and flex sections

• Controlled impedance available for high-speed flex routing

• 100% electrical testing before shipment

Typical Applications

Rigid-Flex PCBs suit compact, high-reliability products where 3D packaging matters:

• Medical Devices and Portable Instruments

• Aerospace-Grade Industrial Equipment

• Automotive Modules

• Communication Devices

• Wearable and Portable Electronics

• Other Compact Assembly Applications

Why Choose Huayihai

• Over 20 years of PCB manufacturing experience

• Rigid-flex lamination capability from prototype to volume

• 3/3 mil trace capability across rigid and flex regions

• Quality management based on ISO 9001, ISO 13485, IATF 16949 and UL

• IPC-A-600 workmanship standards

• Prototype, low-volume, and mass production support

Manufacturing Process

• Gerber file, bend zone, and stack-up review (2–5 working days engineering review)

• Flex core preparation

• Rigid section lamination

• Drilling and plating

• Coverlay and solder mask application

• Surface finish, electrical testing, final inspection

FAQ

Q1: What is a rigid-flex PCB?

A board combining rigid FR-4 sections with flexible polyimide layers in one structure, replacing board-to-board connectors and cables.

Q2: How many rigid layers are supported?

Rigid sections can be built up to 64 layers; flex layer count follows the design.

Q3: Can bend zones contain traces and vias?

Bend zones are designed per IPC flex design rules; traces run through bend areas, vias are kept outside.

Q4: What surface finishes are available?

ENIG, Im Sn, Im Ag, and OSP.

Q5: What is the standard lead time?

3–5 working days for PCB prototypes and batches, after file review is complete.

Request a Quote

Need custom rigid-flex PCBs for compact 3D assembly?

Send us your Gerber files and specifications for a quotation. Learn more at nexuspcba.com.