Flexible PCBs with Higher Layer Count, Wiring Density

Flexible PCBs have long developed from traditional single-sided designs to thinner and smaller but more complex types with a higher number of conductive layers and interconnections. These changes have been driven by the electronics industry’s continued march toward ultracompact but feature-packed devices, including flexible electronics.

Thanks to these advancements, the global market for this PCB category will keep rising at a considerable rate. It is projected to hit $35.865 billion by 2030 at a CAGR of 10.05 percent from 2023, according to Verified Market Research. In 2021, flexible PCBs were valued at $15.412 billion.

Keen on taking advantage of this growing market, Chinese manufacturers will continue to go for a higher layer count and wiring density, specifically four layers and above, finer pitch and smaller hole sizes. Double-sided flexible PCBs currently account for almost half of their shipments, according to suppliers interviewed by Global Sources. The rest are multilayer, single-sided and rigid-flex types.

The key applications are still consumer and automotive electronics, with the latter expected to generate more demand in the coming years. Except in headlights and engines, flexible PCBs may replace automotive wire harnesses because they are lighter, safer and more suitable for fully automatic production. This “will result in a connector reduction of 75 percent, wire harness reduction of 50 percent, space reduction of 70 percent or about one cubic foot of space for the instrument panel, and simplified troubleshooting,” according to Brian Reuter in an article on SD Editorials.

Single-sided flexible PCB, 20z RA copper

Company: Flex Plus (Xiamen) Co. Ltd

A single-sided flexible PCB, the FF5887 from Flex Plus has a 1mil polyimide substrate with 2oz rolled annealed copper, a 1mil polyimide coverlay with 50µm adhesive, a 2mil thermoset polyimide stiffener and an electrolytic tin surface treatment. It is UL-listed.

MOQ: 10 units

Lead time: 3 days

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Double-sided flexible PCB, ENIG

Company: Flex Plus (Xiamen) Co. Ltd

Flex Plus’ DS4869 double-sided flexible PCB has a 1mil polyimide substrate with 1oz rolled annealed copper, a 1mil polyimide coverlay with 25µm adhesive, a 0.2mm polyimide stiffener, an ENIG surface treatment and white legend. It is UL-listed.

MOQ: 10 units

Lead time: 3 days

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Flexible PCB, 0.1mm minimum hole size

Company: Shenzhen Grandtop Electronics Co. Ltd

The GR-PC048 flexible PCB from Shenzhen Grandtop uses a polyimide base material and 1oz minimum copper thickness. Its minimum hole size is 0.1mm, and line width and spacing 2.95mil. This board, with an HASL, OSP or lead-free surface treatment, may have a green, black, white, red, blue or yellow solder mask. Board thickness is 0.11 to 0.5mm.

MOQ: 1 unit

Lead time: 7 days

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Flexible PCB, 1oz minimum copper thickness

Company: Shenzhen Grandtop Electronics Co. Ltd

Shenzhen Grandtop’s GR-PC049 is a flexible PCB with a polyimide base material, 1oz minimum copper thickness, HASL, OSP or lead-free surface treatment and green, black, white, red, blue or yellow solder mask. It has as small as 0.1mm holes, and 2.95mil line width and spacing. Board thickness is 0.11 to 0.5mm.

MOQ: 1 unit

Lead time: 7 days

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Flexible PCB, 0.2mm minimum board thickness

Company: Shenzhen Rway Advanced Electronic Co. Ltd

The FPCB022_1 from Shenzhen Rway has a polyimide base material and stiffener, with the latter also available in FR-4 or metal, and 0.5oz minimum copper thickness. It may have a lead-free HAL, galvanic gold, ENIG, immersion tin or silver, OSP or ENEPIG surface treatment, a green, yellow, black, blue, red, white or orange solder mask and a white, yellow, black or orange legend. This unit is at least 0.2mm thick. It meets IPC, RoHS and UL requirements.

MOQ: 1 unit

Lead time: 5 days

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Flexible PCB, 0.5oz minimum copper thickness

Company: Shenzhen Rway Advanced Electronic Co. Ltd

Shenzhen Rway offers the FPCB010_1 with a polyimide base material, a polyimide FR-4 or metal stiffener, and at least 0.5oz copper and 0.2mm board thickness. Surface treatment may be lead-free HAL, galvanic gold, ENIG, immersion tin or silver, OSP or ENEPIG, solder mask green, yellow, black, blue, red, white or orange and legend white, yellow, black or orange. This unit meets IPC, RoHS and UL standards.

MOQ: 1 unit

Lead time: 5 days

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