Expand the Lifetime of Your Electronic Device Using Flex PCBs

The demand for flex printed circuit boards (PCBs) is growing because of the surge in miniature and flexible electronic devices. As devices get smarter, their PCB assemblies are flooded to ensure all the required functionalities, reliability and performance, while withstanding physical and environmental stresses. These devices also require flexibility and PCBs that would conform to any shape without compromising on the quality and functionality. These are some aspects why flexible printed circuit boards (Flex PCBs) have gained traction over the last few years. They are versatile yet durable, which makes them suitable for modern electronics. They are designed to bend, twist, and withstand dynamic environments, all while maintaining electrical integrity. As an OEM of electronic or electromechanical products, you can consider using flex PCBs in your new products to enhance their functionality and operating life. This post discusses the benefits of using flex PCBs, especially for modern devices, and how they contribute to the durability and long operating life of the device.

Flexible boards are made from bendable thermoplastics such as polyimide, PEN, polyester, PTFE, and Aramid that offer properties such as flexibility, temperature resistance, and heat dissipation among others. These materials also meet other criteria, such as structural stability, mechanical stress, tight bending capabilities, compatibility with various connectors and components, space constraints, weight limitations, and more. They can be customized to meet the exact application and operating environment requirement. In fact, flex PCBs are beneficial in terms of reducing the number of connectors, solder joints, and so on. This reduces the stress on components and the overall risk of failure. Flex PCBs are just perfect for modern electronics ranging from handheld and wearable devices to the infotainment systems in automotive, pacemakers, hearing aids, hospital beds, and more in medical, and drones and navigation systems in aerospace and defense sectors.

Here are some pointers to increase the lifespan of flexible PCBs and in turn that of the devices or systems.

• Choosing the right materials: You need to analyze material properties in terms of temperature, moisture, and corrosion resistance, as well as other physical and chemical properties such as melting point, breaking point, bendability, mechanical strength, and more. Weigh these against your application requirements, operating environment, and budget.
• PCB design: The layout and design are important phases in terms of getting the right output at the end. This includes removing unnecessary stresses, reducing solder joints, and wires, and more. Once the stress on the components reduce, the circuit functions without any issues for a long time. Keep a decent bend radius, which means the level of bending ability without damaging the circuit must be high. Also, ensure ventilation, heat sinks, and so on to build good thermal abilities. A flawless design would lead to minimal or no issues in the future, and hence enable a long operating life.
• Adaptability of flex boards: With the shrinking form factor and complex designs and functionalities, adaptability is a crucial aspect. The boards must fit well into tight or constrained spaces or devices with odd shapes. This is especially important for wearables and IoT devices which may be round, curvy, or of any other shape. Here, the boards must be designed to conform to the shape and size of the device and built considering the required flexibility standards. The right size and fitment go a long way in ensuring a long operating life.
• Use of HDI interconnects: HDI technology enables engineers to design the boards using microvias, blind, and buried vias. This enables to increase the number of components on the board. The engineer can interconnect the inner layers using microvias which offers a larger surface area. This way one can add features and functionalities on a small-sized board without compromising on the quality of the circuit.
• Regular inspection and maintenance: It is important to visually and functionally inspect the device once it is operational. It is also crucial to check the circuitry once in a while with the help of a multimeter. Keep the device away from dirt and contaminants, else use an enclosure if required. Preventive maintenance helps identify issues before they become big.
• Partnering with a reliable PCB assembly service provider: At the onset, it is essential to essential to partner with the right player that has enough experience and can cater to complex design requirements. Also, check for the custom options the offer. Customization is key to right fitment and subsequently lesser issues. All of this helps increase the operating life of the flex PCBs and in turn the device.

If you are an OEM manufacturing mechanical, electromechanical, or electrical devices, parts or products, you may require flex boards. Ensure you partner with a reliable PCB assembly services provider. This is especially essential if you deal in modern electronics or flexible devices. Accelerated Assemblies offers PCB assembly services using custom flex PCBs. The company has several years of market presence and the privilege of working with clients from diverse industries. Contact the team at Accelerated Assemblies via phone or email in case you need further information on our flex PCB assembly offerings and custom options.