Flex Talk: Flex Material Handling—An Inside Peek

As increasingly more designs move to flexible materials to take advantage of space, weight or packaging benefits, it has been clear that flexible circuits require a different set of rules than their rigid counterparts. We spend substantial time working through the design to ensure that he flex is as robust as possible. We also spend quite a bit of time on material selection, again to ensure that the flexible circuit withstands the flexing that will be required and performs properly in the end environment.

One thing we do not often talk about is what happens behind the scenes during the fabrication and assembly of the flexible circuit. What types of special handling considerations are in place throughout the manufacturing process to accommodate these thin materials? When you are auditing a potential new supplier, what should you be asking about and looking for in their procedures?

Undoubtedly, the largest source of defects in flexible circuit manufacturing can be traced back to material handling. Drawing from my own knowledge and soliciting the expertise of several industry veterans involved in flex circuit manufacturing—David Moody with Lenthor Engineering, Anaya Vardya with American Standard Circuits, Jim Barry with Eltek, and Mike Vinson with Averatek—I have put together an insider’s view of the nuances involved in manufacturing flexible circuits.

To read the full version of this article which appeared in the March 2017 issue of The PCB Magazine, click here.

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2017

Flex Talk: Flex Material Handling—An Inside Peek

04-03-2017

As increasingly more designs move to flexible materials to take advantage of space, weight or packaging benefits, it has been clear that flexible circuits require a different set of rules than their rigid counterparts. We spend substantial time working through the design to ensure that he flex is as robust as possible.

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Flex Talk: Final Surface Finish—How Do You Choose?

01-26-2017

There are so many final surface finish options to choose from today. How do you decide which is best? HASL—both tin-lead and lead-free—immersion tin, immersion silver, ENIG, OSP, and ENIPIG are the primary finishes used in PCB fabrication.

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2016

Flex Talk: A Glimpse into PCB Sales

12-28-2016

Summarizing the feedback from both customers and manufacturers, the most successful PCB salespeople are organized, take a genuine interest in their customers’ needs and business challenges, have a better than average understanding of the PCB industry, fully understand the manufacturer’s strengths and capabilities and advocate for both to find the best solution.

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Flex Talk: Troubleshooting Flex Circuit Applications for Mil/Aero Projects

10-06-2016

I imagine that everyone has been in this position at one time or another: Despite everyone’s best attempt at creating the perfect design, PCB fabrication and assembly, something goes wrong and the troubleshooting begins.

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Flex Talk: Inaugural West Coast Geek-A-Palooza a Fun-filled Success

05-24-2016

Geek-A-Palooza kicked off the 2016 schedule May 12 in Irvine, California. Historically, Geek-A-Palooza has been held in Minneapolis but is expanding this year to include Orange County and Boston as well.

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Flex Talk: PCB Sourcing? One Size Does Not Fit All

04-18-2016

When analyzing a set of PCBs to improve yields and maximize profits, the first place to start is with a critical review of each PCB design. Are there any attributes that are pushing your manufacturer’s standard design rules? If so, is this necessary to the design or is there another approach that could improve the manufacturer’s yields, reduce cost, and ultimately increase profit?

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2015

Flex Talk: Thoughts on the IPC Flexible Circuits–HDI Forum

11-19-2015

As an attendee at the IPC Flexible Circuits–HDI Conference held October 28–30, I found myself in a room of people, all eager for technical information, with the opportunity to reconnect with industry friends and to make new connections. The audience was diverse with young people, new to our industry, sitting alongside industry veterans willingly sharing their knowledge and passion for HDI design and flexible circuit technology.

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Designing Flex Circuits for Domestic Prototyping

08-20-2015

Designing a flex circuit to be prototyped domestically? No problem. Designing a rigid-flex circuit for production offshore? Got it. Designing a part that will be prototyped domestically with a seamless transition to offshore production? That can be a little more challenging.

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Rigid Flex: Total Cost Comparison

07-09-2015

The transition to a rigid-flex design from the traditional approach of using cable assemblies to join two or more PCBs has obvious benefits—space, weight, packaging, reliability and increased currently carrying capabilities. Yet many times the perception that rigid-flex is a high-cost solution causes designers and engineers to hesitate.

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Primary Cost Drivers for Flex Circuit Designs

06-25-2015

Someone once told me that the potential applications for flexible circuits are really only limited by our imaginations. After pondering that a bit, I had to agree. In fact, one of the things I like best about what I do is that moment during a discussion when I can see the light bulb go off in a designer's head.

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The Flex-to-Fit Approach

06-04-2015

The flex-to-fit concept reminds us that creativity and engineering go hand-in-hand. When there is not ample space for a conventional approach, this process, which is the convergence of the mechanical world and the electronics world, results in the ability to design a flexible circuit along the contour of an existing, irregularly shaped structure.

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