Trusted Flexible PCB Manufacturer
Highleap provide flexible PCB up to 8 layers, whether prototype or mass production. Please call or submit your Gerbers/specs today for a fast and secure quote.
FPC Manufacturing Services
Highleap Electronics specializes in high-quality flexible and rigid-flex PCB manufacturing, offering a wide range of types including multi-layer flex PCBs, ultra-thin, and heavy copper flex circuits. From prototypes to high-volume production, we provide reliable solutions with fast turnaround times. Let us help you bring your next flex circuit to life with precision and efficiency.
Multilayer Flex Circuits
Ultra-long Flexible PCB
High-frequency Flexible PCB
Gold Finger Flex PCB
We are experts in crafting Flexible PCBs from a wide range of high-quality materials, including polyimide, PET, and more, offering unparalleled versatility and performance for all your advanced, compact, and dynamic electronic applications. No matter the complexity, we deliver custom solutions that push the boundaries of innovation!
Highleap Electronics Multi-Layer Flex PCB Services
At Highleap Electronics, we specialize in providing a comprehensive range of high-quality multi-layer flex PCBs designed to meet the needs of advanced electronic applications. Our services include:
- Multi-layer flex PCBs with up to 16+ layers
- HDI (High-Density Interconnect) flexible PCBs
- AP-Pyralux by DuPont
- FELIOS from Panasonic
- TK-Flex PTFE (DuPont)
- Non-flow prepregs such as GF, GI, and acrylic
- Adhesive-based and adhesive-free construction options
- Heavy copper flex PCBs with copper weights up to 10 oz
- Large format flexible circuits for complex designs
- Ultra-long flexible PCBs for specific applications
- Sculptured and custom-shaped flex circuits
- Heater flex circuits for temperature-sensitive applications
- Differential copper flexible PCBs for improved performance
- Surface finishes like anti-tarnish, immersion silver, tin, solder, electroplated nickel/gold, and ENIG (Electroless Nickel Immersion Gold)
- EMI/RFI shielding solutions to prevent interference
- Controlled impedance for precise signal integrity
- Film and polyimide stiffeners for added durability
- Stainless steel and aluminum stiffeners for structural integrity
- Comprehensive flexible circuit assembly services
- No minimum order quantity (MOQ) or minimum order value (MOV) for prototypes
Our extensive capabilities ensure that we can support the development of sophisticated electronic devices across various industries, delivering precision, durability, and outstanding performance. Whether you need standard or customized solutions, we are committed to providing reliable, high-quality products that meet your exact requirements.
Flexible PCB Manufacturing Process
At Highleap Electronics, we specialize in a wide range of flexible PCB solutions, offering advanced manufacturing capabilities for various industries. From multi-layer flex PCBs to heavy copper designs, we provide customized solutions to meet the specific needs of our clients. Our flexible PCBs are ideal for applications where space, durability, and high-performance connectivity are crucial.
In the video, we have highlighted some of the key steps involved in the manufacturing process of flexible PCBs. If you are interested in learning more about the detailed process, from material selection to surface finishes and assembly, feel free to contact us. Our team at Highleap Electronics is here to provide you with expert insights and guide you through the specifics of flexible PCB manufacturing.
Whether you need a prototype or large-scale production, Highleap Electronics can support your project with precision, quality, and timely delivery. Let us help you achieve the best results for your flexible PCB needs.
Highleap Electronics Flex PCB Capabilities
At Highleap Electronics, we offer a wide range of capabilities for manufacturing flexible PCBs that meet the rigorous demands of modern electronic applications. Our expertise ensures that we can handle designs ranging from simple to highly complex, providing robust solutions across industries. Below is an overview of the key features and specifications we support for flex PCB production.
Flex PCB Manufacturing Specifications:
- Max Layers: Up to 16 layers
- Inner Layer Minimum Trace/Space: 3/3 mil
- Outer Layer Minimum Trace/Space: 3.5/4 mil
- Inner Layer Maximum Copper Thickness: 2 oz
- Outer Layer Maximum Copper Thickness: 2 oz
- Minimum Mechanical Drilling: 0.1 mm
- Minimum Laser Drilling: 0.1 mm
- Aspect Ratio (Mechanical Drilling): 10:1
- Aspect Ratio (Laser Drilling): /
- Press Fit Hole Tolerance: ±0.05 mm
- PTH Tolerance: ±0.075 mm
- NPTH Tolerance: ±0.05 mm
- Countersink Tolerance: ±0.15 mm
- Board Thickness: 0.1 – 0.5 mm
- Board Thickness Tolerance (<1.0 mm): ±0.05 mm
- Board Thickness Tolerance (≥1.0 mm): /
- Impedance Tolerance: Single-Ended: ±5Ω (≤50Ω), ±10% (>50Ω); Differential: ±5Ω (≤50Ω), ±10% (>50Ω)
- Minimum Board Size: 5*10 mm
- Maximum Board Size: 9*14 inches
- Contour Tolerance: ±0.05 mm
- Minimum BGA: 7 mil
- Minimum SMT: 7*10 mil
- Surface Treatment Options: ENIG, Gold Finger, Immersion Silver, Immersion Tin, HASL, OSP, ENEPIG, Flash Gold, Hard Gold Plating
- Solder Mask Colors: Green Solder Mask, Black PI, Yellow PI
- Minimum Solder Mask Clearance: 3 mil
- Minimum Solder Mask Dam: 8 mil
- Legend Options: White, Black, Red, Yellow
- Min Legend Width/Height: 4/23 mil
- Strain Fillet Width: 1.5 ±0.5 mm
Why Choose Highleap for Flex PCB Manufacturing?
Highleap Electronics stands out as a leader in flexible PCB production, offering not just the flexibility of design but also advanced features such as high-density interconnects (HDI) and multi-layer configurations. With our comprehensive range of manufacturing specifications, we ensure the highest quality and precision, making us the ideal choice for your flex PCB needs.
Whether you’re working on high-frequency circuits, complex flexible designs, or high-power applications, our team is ready to provide a tailored solution to meet your specific requirements. Reach out today to learn more about how we can support your next flex PCB project.
Flexible PCB Solutions at Highleap Electronics
At Highleap Electronics, we go beyond just providing flexible PCBs—we offer comprehensive Flexible PCB solutions tailored to meet the unique needs of your projects. Whether you need high-density designs, customized shapes, or robust performance in extreme conditions, we are committed to delivering solutions that drive innovation and performance.
Tailored Designs
We collaborate closely with you to create flexible PCB designs that match your specifications, whether for consumer electronics, medical devices, automotive systems, or other specialized industries.
End-to-End Service
From concept to final assembly, we provide full-service solutions, including design, prototyping, testing, and mass production. With flexible PCB assembly capabilities in-house, we ensure quality, speed, and reliability at every step.
High-Quality Materials
We use the best materials available to ensure that your flexible PCBs not only meet but exceed industry standards for durability, heat resistance, signal integrity, and performance.
Cost-Effective and Scalable
Our flexible PCB solutions are optimized for both cost-efficiency and scalability. Whether you’re looking for prototypes or need to scale up production, we offer flexible solutions that meet your budget and volume requirements.
Make Your Flex PCB Design a Reality！
Being a trusted flexible printed circuit board manufacturer with a vast industry experience, we specialize in flexible circuit boards.
Are you searching for a manufacturer to meet your flexible PCB needs? Look no further than Highleap!
Advantages of Flex PCB
Flexible PCBs offer exceptional design flexibility, allowing them to be folded, bent, or customized into various shapes and sizes, making them ideal for compact, complex designs. Their lightweight construction and reduced interconnections provide remarkable durability, enabling them to withstand shock, vibration, and external forces. Additionally, flexible PCBs support higher circuit densities with thinner layers and smaller components, and they offer superior heat dissipation, particularly with polyimide materials that resist high temperatures better than traditional FR4 boards.
These PCBs also contribute to product miniaturization by significantly reducing weight and size, improving portability and functionality. With shorter interconnect lengths, flexible PCBs minimize signal loss, impedance issues, and wiring errors, ensuring reliable and high-speed performance. Furthermore, they optimize material usage and streamline assembly processes, ultimately reducing manufacturing costs while maintaining high electrical performance.
Applications for Flex PCB
Medical devices
At medical application, flex PCBs are the ideal choice for biometric sensors, monitoring devices, medical imaging equipment and medical devices implanted inside the human body, such as pacemakers and neurostimulators. They can be customized to provide long-term, stable performance.
Automotive
The automotive industry relies heavily on compact and complex electronics systems, including advanced driver assistance systems (ADAS), infotainment systems, and sensors. Flex PCBs can be intricately designed to fit.
Lighting
Flex PCBs provide the required flexibility to accommodate the shape and size variations needed for different lighting installations. They also enable efficient heat dissipation, crucial for LED longevity and performance.
Industrial machinery
Industrial machinery is subjected to constant vibration and mechanical shock. Flex PCBs are more resilient in these environments compared to rigid PCBs.And many industrial processes generate heat, and machinery must operate in high-temperature conditions. Flex PCBs can be manufactured with materials that have excellent thermal resistance.
Consumer products
Materials for Flex PCB
The following are some common flex pcb materials：
Adhesives
The adhesive selection depends on the application requirements and conductor dimensions. We offer popular adhesives such as acrylics, epoxies, pressure-sensitive adhesives (PSAs), and adhesive-free base materials.
Finishes
We provide a range of final finishes to meet your project’s needs. Options include ENIG (Electroless Nickel Immersion Gold), HASL (Hot Air Solder Leveling), Pb-free HASL, immersion silver, immersion tin, and even organic materials. Each finish option has different properties and is best suited for specific applications.
Insulators
Choosing the right insulating material is crucial to ensure the long-term success of your flexible PCB application. Our insulators combine various materials, including flexible solder masks, photo-imageable coverlays, polyester, polyethylene naphthalate (PEN), polyethylene terephthalate (PET), polyimides, screen-printed dielectric insulators, and solder masks. These materials come in different form factors and thicknesses to meet diverse needs.
We provide high quality materials.
- DuPont: Pyralux AP, LF, FR, high-speed Pyralux TK (Teflon-Kapton)
- Isola: 370HR, FR406, FR408,FR408HR
- Rogers: Teflon
- Arlon: Polyimide, metal-core.
Manufacturing
Suggestions
Graphic Overlays
Graphic Overlays: Graphic overlays are transparent covers made of acrylic or polyester that provide a user interface for PCBs. These overlays incorporate elements like LEDs, LCDs, and switches, allowing users to interact with the underlying circuit as desired.
Laser Skived Slots and Holes
In the past, flex circuits were manually cut with razors, relying on the skill of the operator. Modern laser technology allows for precise and controlled cutting, enabling the creation of intricate circuit designs with even greater precision in flexible PCBs.
Pressure-Sensitive Adhesives
Pressure-sensitive adhesives (PSAs) are adhesive materials that secure objects by applying pressure without the need for soldering. These adhesives are commonly used in PCB applications to hold circuit components in place securely.
Stiffeners
To provide additional support in areas where flex circuits may require reinforcement, stiffeners made of FR4 and polyamide are often added. These stiffeners enhance the strength and longevity of the flexible circuit, ensuring reliable performance.
Hot Bar Solder
Hot bar soldering is an efficient alternative to standard connections, eliminating the need for connectors between hardboards and flex circuits. This method creates a robust and cost-effective connection, enhancing durability and overall efficiency.
Panelization
Panelization involves assembling PCBs in large panels containing multiple units. This process significantly speeds up the flex circuit assembly, especially in pick-and-place assembly lines. Once assembled, the units can be easily separated.
Shielding
Electromagnetic interference (EMI) has historically posed challenges, particularly in applications where electronic components are sensitive to interference. Advancements in shielding technology have mitigated this issue, reducing noise and controlling signal line impedance more effectively.
Engineer Services of Flex PCB
If you choose flex pcb manufacturing, we will provide the following engineering services.
Design Rule Check
With our comprehensive design rule check (DRC) capabilities, we meticulously review each chip layout to ensure compliance with essential parameters and design rules. By partnering with our strategic manufacturing partners, we maximize space utilization and deliver high-performance boards tailored to your specific application requirements.
Controlled Impedance Modeling
When your PCBs require controlled impedance, we excel in performing accurate controlled impedance modeling. We adjust copper thickness and optimize the physical relationships between board components to achieve precise impedance values. Our capabilities ensure the production of high-quality boards capable of operating within the 100 MHz to 3 GHz frequency range.
Panelization
PCB panelization plays a crucial role in enhancing accuracy during automated assembly and ensuring the quality of your boards. At MCL, we offer panelization services for various PCB designs, including traditional rectangular boards and more intricate polygonal designs. Our panelization expertise guarantees precise and efficient assembly processes.
DFX-to-Gerber Conversions
If your company utilizes DFX files generated by computer-aided design (CAD) programs, we offer seamless DFX-to-Gerber file conversions. By converting your files to the more standard and efficient Gerber format, we streamline the production process, reduce errors, and enable faster delivery times. Trust MCL to handle the conversion process with precision and reliability.
Choose Highleap as Your PCB Manufacturer
Full Expertise
We have rich experience in all kinds of PCB manufacturing and assembly.From component procurement to product delivery, we can complete every step with high quality.
Strong Supplier Network
With 10 years of experience in the PCB industry, Highleap owns a supplier network that provides us with reliable access to get high-quality components at competitive prices.
Strict Quality Control
At each process, we strictly control the quality by implementing a variety of testing and inspections to ensure that each PCBA reaches the highest quality standard.
Take a Quick Quote
Discover how our expertise can help with your next PCB project.