When to use flex
It’s obtaining more challenging to fit everything in the box; it’s likewise obtaining even more expensive. One option promising to aid designers fulfill the size constraint head on is rigid flex PCB technology, but many design groups attempt to avoid using rigid flex PCBs when item price is a concern. Yet is it really as pricey as we assume?
To begin with, take into consideration the price of the traditional rigid-cable-rigid PCB assembly to one based upon rigid-flex innovation. The former construction functions well for short-run designs; nevertheless, it requires ports on the interconect as well as each board, all of which increase BoM cost Furthermore, the rigid-cable-rigid design is prone to ‘cool joints’, and also decreased life span. In contrast, rigid-flex circuits eliminate these joints, making them a lot more trustworthy and able to supply on the whole higher product high quality and also durability. So while rigid-flex PCB innovation is certainly not new, numerous factors to consider currently make it a lot more viable– not the least of which is expense.
It’s obtaining more challenging to fit everything in the box; it’s likewise obtaining even more expensive. One option promising to aid designers fulfill the size constraint head on is rigid flex PCB technology, but many design groups attempt to avoid using rigid flex PCBs when item price is a concern. Yet is it really as pricey as we assume?
To begin with, take into consideration the price of the traditional rigid-cable-rigid PCB assembly to one based upon rigid-flex innovation. The former construction functions well for short-run designs; nevertheless, it requires ports on the interconect as well as each board, all of which increase BoM cost Furthermore, the rigid-cable-rigid design is prone to ‘cool joints’, and also decreased life span. In contrast, rigid-flex circuits eliminate these joints, making them a lot more trustworthy and able to supply on the whole higher product high quality and also durability. So while rigid-flex PCB innovation is certainly not new, numerous factors to consider currently make it a lot more viable– not the least of which is expense.
Mimic the price.
In some layouts, rigid flex will certainly not be a feasible choice, and you have to do your due diligence in determining the break-even point where the prices are about equal. This type of rate simulation can be done by taking into consideration the overall estimated expenses for fabrication as well as assembly. The PCBs can be priced estimate prior to design, as long as the parameters of design are well comprehended (as an example, the layer stack, approximated through space, track and matter proportions, etc.).
We carried out a manufacturing cost simulation with a real rigid flex design and also a comparative rigid-cable-rigid equivalent. The part BoMs for contrast differed only in the wire and adapters needed for the non-flex variation. For our simulation, the conventional design is consisted of four-layer boards that utilize flexible cable and also ports in between them, while the rigid-flex design is a four-layer PCB with 2 inner flex layers. Manufacturing expense for both layouts is based on genuine PCB maker quotes, and consists of the cost of assembly.
In some layouts, rigid flex will certainly not be a feasible choice, and you have to do your due diligence in determining the break-even point where the prices are about equal. This type of rate simulation can be done by taking into consideration the overall estimated expenses for fabrication as well as assembly. The PCBs can be priced estimate prior to design, as long as the parameters of design are well comprehended (as an example, the layer stack, approximated through space, track and matter proportions, etc.).
We carried out a manufacturing cost simulation with a real rigid flex design and also a comparative rigid-cable-rigid equivalent. The part BoMs for contrast differed only in the wire and adapters needed for the non-flex variation. For our simulation, the conventional design is consisted of four-layer boards that utilize flexible cable and also ports in between them, while the rigid-flex design is a four-layer PCB with 2 inner flex layers. Manufacturing expense for both layouts is based on genuine PCB maker quotes, and consists of the cost of assembly.
Find your break-even factor
As the project volume depicted in Figure 1 hits 100 units, the rigid-flex design becomes a more cost-effective option compared to the traditional design approach. A crucial factor for this price financial savings is that rigid-flex circuits do not utilize connectors/cables or require any connector assembly. They showcase raised dependability as well as process yields. But that’s just the superficial.
Since rigid flex PCBs need no cable television assembly, their total assembly effort is reduced, as is their examination intricacy– both of which driving a car down price. Additionally, less parts need to be purchased, minimizing the supply chain danger. Rigid flex PCBs can be designed to make product upkeep easier and therefore, even more economical over the course of the item lifecycle.
As the project volume depicted in Figure 1 hits 100 units, the rigid-flex design becomes a more cost-effective option compared to the traditional design approach. A crucial factor for this price financial savings is that rigid-flex circuits do not utilize connectors/cables or require any connector assembly. They showcase raised dependability as well as process yields. But that’s just the superficial.
Since rigid flex PCBs need no cable television assembly, their total assembly effort is reduced, as is their examination intricacy– both of which driving a car down price. Additionally, less parts need to be purchased, minimizing the supply chain danger. Rigid flex PCBs can be designed to make product upkeep easier and therefore, even more economical over the course of the item lifecycle.
What about design time?
While the expense of manufacturing, assembly, screening, as well as logistics are essential consider taking into consideration the stability of rigid flex PCB innovation for any offered design, job and advancement costs could not be forgotten. Rigid flex PCB design usually requires the mechanical team to aid with the flex portion of the design, and PCB integration with the final product. The procedure is really time pricey as well as consuming, as well as susceptible to mistakes.
Making matters worse, PCB design devices commonly ignore the folding as well as fitting aspects of rigid flex design. Rigid flex modern technology design requires developers to function as well as think in 3D. The flex portions can be folded up, bented and also rolled to follow the design of the mechanism. Standard PCB design devices don’t support 3D board design or the meaning and simulation of bends as well as folds up in the flex portion of the design. They do not also support the interpretation of different layer heaps in various parts of the design, consisting of the locations comprising the design’s flex component.
As a result of this, rigid-flex designers have been compelled to manually translate both the inflexible and also flex areas of their 3D design right into a level, 2D depiction suitable for fabrication. They have to by hand document all locations of the design that are flex, and dual check that no vias or parts have actually been put near the changes in between the design’s stiff and flex portions. This procedure is controlled by several added guidelines, most of which are, not too remarkably, not sustained by the majority of PCB design software program.
As a whole, the additional effort it has required to design rigid flex PCB as compared to common stiff PCBs utilizing standard PCB design software has actually made them much less set you back affordable. Luckily, modern-day design devices with advanced 3D abilities, as well as support for the definition as well as simulation of bends as well as folds in the flex part of the design, in addition to the meaning of different layer stacks in different parts of the design, are currently offered. These devices normally get rid of the need to deal with the flex part of the design with mechanical CAD tools, conserving designers and also design teams both money and time.
Design in 3D to guarantee success
Early sychronisation in between the developers and also the circuit board manufacturer, sustained by the use of a modern PCB design device, is an additional aspect making rigid-flex modern technology a more cost-effective choice. Rigid-flex styles require closer cooperation between the developer as well as producer than typical rigid board styles. The tradeoffs needed to create a successful rigid-flex design equate to a set of design rules the designer could develop with the maker’s input. These factors to consider consist of the variety of layers in the design, materials choices, suggested sizes for vias as well as traces, bond approaches, as well as dimensional control. With the right design device, these considerations can be plainly specified and also provided the appropriate weight they are worthy of early on so that the rigid-flex PCB could be properly maximized, further enhancing its overall cost.
While the expense of manufacturing, assembly, screening, as well as logistics are essential consider taking into consideration the stability of rigid flex PCB innovation for any offered design, job and advancement costs could not be forgotten. Rigid flex PCB design usually requires the mechanical team to aid with the flex portion of the design, and PCB integration with the final product. The procedure is really time pricey as well as consuming, as well as susceptible to mistakes.
Making matters worse, PCB design devices commonly ignore the folding as well as fitting aspects of rigid flex design. Rigid flex modern technology design requires developers to function as well as think in 3D. The flex portions can be folded up, bented and also rolled to follow the design of the mechanism. Standard PCB design devices don’t support 3D board design or the meaning and simulation of bends as well as folds up in the flex portion of the design. They do not also support the interpretation of different layer heaps in various parts of the design, consisting of the locations comprising the design’s flex component.
As a result of this, rigid-flex designers have been compelled to manually translate both the inflexible and also flex areas of their 3D design right into a level, 2D depiction suitable for fabrication. They have to by hand document all locations of the design that are flex, and dual check that no vias or parts have actually been put near the changes in between the design’s stiff and flex portions. This procedure is controlled by several added guidelines, most of which are, not too remarkably, not sustained by the majority of PCB design software program.
As a whole, the additional effort it has required to design rigid flex PCB as compared to common stiff PCBs utilizing standard PCB design software has actually made them much less set you back affordable. Luckily, modern-day design devices with advanced 3D abilities, as well as support for the definition as well as simulation of bends as well as folds in the flex part of the design, in addition to the meaning of different layer stacks in different parts of the design, are currently offered. These devices normally get rid of the need to deal with the flex part of the design with mechanical CAD tools, conserving designers and also design teams both money and time.
Design in 3D to guarantee success
Early sychronisation in between the developers and also the circuit board manufacturer, sustained by the use of a modern PCB design device, is an additional aspect making rigid-flex modern technology a more cost-effective choice. Rigid-flex styles require closer cooperation between the developer as well as producer than typical rigid board styles. The tradeoffs needed to create a successful rigid-flex design equate to a set of design rules the designer could develop with the maker’s input. These factors to consider consist of the variety of layers in the design, materials choices, suggested sizes for vias as well as traces, bond approaches, as well as dimensional control. With the right design device, these considerations can be plainly specified and also provided the appropriate weight they are worthy of early on so that the rigid-flex PCB could be properly maximized, further enhancing its overall cost.
There’s no denying that existing industry patterns as well as consumer demands are pressing developers and also design groups to their restrictions, forcing them to seek new alternatives to the electronic design challenges they now deal with. These difficulties, and particularly the requirements being put on today’s mobile phones, are pressing rigid-flex modern technology right into the mainstream, and also making it much more readily viable for a range of applications. The accessibility of modern PCB design devices that support 3D product advancement, very early cooperation, and all required rigid flex definitions and also simulation significantly reduce the discomfort of rigid flex PCB design as well as make it a lot more engaging solution– one that under the right circumstances is less expensive compared to rigid-cable-rigid PCB design. For today’s design groups, that choice might simply mean the distinction between product success or failing.
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