Software For Flexible PCBs
When designing a PCB, it’s important to follow PCB layout standards that dictate where and how components should be placed. These standards can help ensure that the circuit board is built to last and won’t cause any future problems with electrical noise or signal interference.
For flex PCBs, there are additional layout rules that should be followed to ensure that the board will have enough strength and flexibility to withstand repeated bending. For example, flex circuits should be designed with pads that are oversized and have large corner radius to prevent them from getting torn when the pcb is bended. Using hatched copper pours instead of solid copper can also increase the strength and flexibility of the flex circuit.
It’s also important for designers to use a high-quality, flexible pcb board adhesive that will stick well to the surface of the flex PCB without tearing or peeling off during the assembly process. Adhesive materials like acrylic, epoxy, and pressure-sensitive adhesives (PSA) are great options for flex PCBs.
Design Software For Flexible PCBs
Lastly, a good design will include mechanical stiffeners that can be added to specific areas of the flex circuit to provide some extra structural support. Typical stiffener locations include the connector, edge connections, and mounting holes. Stiffeners are made from rigid material (usually FR4) that is laminated to the flex PCB to make it stronger and more resilient.
Another common feature of a good flex PCB design is the inclusion of a power/ground plane layer and shielding to minimize impedance problems. While solid copper is the most popular option for these plane layers, it’s important to note that this can significantly reduce the flexibility of the flex circuit. Instead, a better option is to use a hatched copper pattern that is statistically optimized for a given layout.
Whether you’re designing a flex or rigid-flex circuit, the best way to avoid costly errors is to work with a world-class PCB design software that has a strong flex/rigid-flex stack-up and layout tools. Altium Designer has the ability to verify flex/rigid-flex clearances and other mechanical constraints in 3D, providing a significant advantage over standard routing and layout tools that only operate in 2D.
Furthermore, flexible PCBs offer enhanced reliability and durability compared to their rigid counterparts. The absence of solder joints and connectors reduces the risk of mechanical failure due to vibration, shock, or repeated bending, making flexible PCBs well-suited for applications subjected to harsh operating environments. Additionally, the use of high-quality materials and advanced manufacturing techniques ensures excellent thermal stability and resistance to moisture and corrosion, further enhancing the reliability and longevity of flexible PCB-based systems.
A top-rated PCB design software like Altium offers a unified rules-driven design model that works for both rigid and flex circuit boards. You can also leverage powerful simulation and analysis capabilities to eliminate expensive design mistakes before they even occur in production. With these features, you’ll be able to deliver a superior flex or rigid-flex PCB that is ready for manufacture.