FPC Assembly

What is FPC?

A flexible printed circuit board (FPC), made of polyimide (PI) or polyester (PET), offers the ability to bend and fold, making it a versatile option. It comes in various configurations including single-sided, double-sided, and a range of colors such as yellow, black, white, and transparent. Known for its lightweight and thin profile, flexible PCBs find extensive use in applications that demand flexibility and adaptability.

Manufacture Process

  1. Design and Layout: The initial step involves creating the design and layout of the flexible printed circuit board (FPC) using specialized software.

  2. Substrate Preparation: The substrate material, such as polyimide or polyester, is prepared by cleaning and coating it with an adhesive or conductive material.

  3. Etching: A photoresist is applied to the substrate, and the circuit pattern is printed using photolithography. Unwanted copper is etched away, leaving behind the desired circuit traces.

  4. Drilling: Holes or vias are drilled into the substrate to allow for component mounting and interconnection between different layers of the FPC.

  5. Plating: The drilled holes and circuit traces are plated with a thin layer of metal, typically copper, to enhance conductivity and durability.

  6. Coverlay Application: A protective layer, called a coverlay, is applied to the top surface of the FPC to safeguard the circuitry.

  7. Component Assembly: Electronic components are mounted onto the FPC using surface mount technology (SMT) or through-hole technology (THT), based on design requirements.

  8. Testing and Inspection: The assembled FPC undergoes rigorous testing and inspection to ensure it meets quality and performance standards, including automated optical inspection (AOI), in-circuit testing (ICT), and functional testing.

  9. Final Finishing: The FPC is trimmed, cleaned, and may receive surface finishes or coatings to protect the circuitry and enhance functionality.

  10. Packaging and Delivery: The finished FPCs are packaged and prepared for shipment to customers or integration into electronic products.

Advantages of FPC

FPCs are chosen for their flexibility and conductivity, making them ideal for applications where mechanical strength is not a primary requirement. Their thin and lightweight nature makes them perfect for portable devices like cell phones, digital cameras, and walkie-talkies, while they can also be utilized in larger devices such as peripheral and power supplies.

  • Weight and Space Reduction: FPCs offer the advantage of reducing weight and saving space in devices that require connectivity without the need for bulky electrical connectors. For instance, in a portable GPS device, an FPC can efficiently connect a small battery to the main unit, which already has an internal rechargeable battery. By utilizing an FPC, the device can accommodate additional components such as a display and buttons, optimizing space utilization.

  • Easy Customization: The flexibility of FPCs allows for easy customization and modification. They can be cut to the desired size and easily removed from the circuit board, making them highly adaptable for new uses. For example, by adding an FPC with extra components to an existing board, it is possible to create a completely new electronic product. This versatility enables the enhancement of functionalities in devices like a car radio by connecting an external battery through an FPC without the need for a full replacement.

  • Meeting Dynamic Flexing Requirements: FPCs are particularly suitable for use in portable devices due to their flexibility and lightweight nature. They can conform to the shape of flexible products, such as cell phones, or be tailored by cutting them to the desired size for new circuit board designs. These properties make FPCs an ideal choice for consumer electronic products that require dynamic flexing capabilities while maintaining optimal performance.

  • Flexing for Easier Installation and Service: FPCs find applications in solar panels for homes and buildings, satellites, power generators, and electric vehicles. They offer the advantage of easy installation in places where building a roof or challenging landscapes pose difficulties. The flexibility of FPCs allows them to conform to various environments while maintaining electrical connectivity between components. In electric vehicles, FPCs provide a lightweight structure without compromising strength, ensuring durability during operation.

  • Impedance Control: FPCs are made from high-quality materials with excellent electrical conductivity, making them suitable for applications requiring impedance control. Compared to soldered connections, FPCs offer the advantage of easily controlling impedance, which is crucial for mobile devices like cell phones. This enables optimal signal transmission and performance in consumer electronic products.

  • Expandability: Electronic devices such as solar panels and electric vehicles often require expansion to accommodate technological advancements or evolving user needs. FPCs facilitate this expandability by serving as connectors for various additional components that can be added later to fulfill new functionalities. This flexibility allows for the seamless integration of new features into existing systems.

  • Increased Reliability and Repeatability: In the case of solar panels, FPCs undergo rigorous testing, including mechanical assessments, to ensure stability and reliability once installed. This meticulous evaluation guarantees the product’s ability to perform consistently in diverse environmental conditions. By using FPCs, manufacturers can enhance the reliability and repeatability of their electronic systems, ensuring long-term functionality and customer satisfaction.

  • Thermal Management: Our designed products leverage FPCs with excellent thermal management capabilities. Unlike soldered connections, FPCs can be easily replaced or repositioned to alter their thermal properties. This flexibility ensures optimal performance and heat dissipation, resulting in reliable and efficient operation.

  • Enhanced Aesthetics: By incorporating thin film technology, FPCs can be designed to be exceptionally thin, reducing the overall size of the end product and enhancing its visual appeal. Components are printed directly onto the FPC, maintaining their functionality and seamless integration while creating a sleek and modern appearance.

  • Elimination of Connectors: FPCs eliminate the need for connectors, enabling easy removal and reconnection to other boards without requiring product disassembly. This streamlined design not only simplifies access to cables but also reduces production costs and ensures a clean and clutter-free product appearance.

  • Cost-Effective Assembly: In many cases, FPCs contribute to cost savings during assembly. For instance, semiconductor companies can utilize FPCs in combination with other components to create circuit boards, increasing functionality while reducing production expenses.

  • Increased Scalability: With their flexibility and lightweight construction, FPCs enable the connection of multiple components onto a central board, facilitating the creation of larger devices with enhanced performance capabilities.

  • Uniform Electrical Characteristics for High-Speed Circuitry: Manufactured using high-quality materials and techniques similar to optical fiber, FPCs deliver consistent and reliable electrical characteristics for high-speed circuitry. This ensures stable operation even at very high speeds, without compromising performance.

  • Improved Signal Integrity: FPC designs are optimized to enhance signal integrity by minimizing noise, reflection, and electromagnetic interference (EMI). These advancements result in improved transmission performance and robust resistance to external interferences, ensuring the integrity of critical signals.


Click or drag a file to this area to upload.
Please upload your PCB Files(.zip, .rar, .7z, .pcb, .pcbdoc, .brd) or Bom Files(.xls, .xlsx, .crv)within 20Mb
Scroll to Top