Flexible Circuit Assemblies
High-Quality Flex Circuit Assembly Manufacturing
Flexible circuit assemblies are sometimes recommended over traditional rigid circuit assemblies because of the ability to bend and conform the circuit to virtually any shape. In addition, any component that can be mounted to a traditional circuit board can be mounted to a flex circuit. This includes surface mount (SMT) components, thru hole components, wires, cables, and connectors, among others.
A single flexible circuit assembly can replace multiple circuits to save space in a product design. Applications where this feature is most beneficial include aerospace, automotive, and medical devices, though compact consumer products may also benefit from this technology.
Tramonto Circuits is a rigid-flex and flexible printed circuit manufacturer with a historical quality ratio of over 99%. Our capabilities and expertise are in automated or hand assembly using flex circuit assembly fixtures. Prototypes and functional tests are available by request. We offer assembly as individual circuits or panelized to meet customer requirements and perform multiple quality checks during production, as well as a final inspection before shipping.
Some Key Points
- Thin, light weight and durable enough to outlast your product life cycle
- Wide operating temperature range from ‐55°C ‐ 150°C
- Mount all component types – surface mount (SMT), thru – hole, crimp on pins, wire bond, BGA
- Meets IPC‐6013 Qualifications and Performance Specifications for Flexible Printed Boards
Request a Quote
Receive a quote for most projects within 24 hours. Engineers respond to your inquiry and are available to answer questions and discuss design specifications.
Flex Circuit Assembly Capabilities
| Specification | Typical | Non-Typical |
| Layer Count | 1 ‐ 6 conductive layers | |
| Trace/Space | .004”/.004” typical | .003”/.003” non‐typical |
| Current Carrying Capacity | few milliamps to several amps | |
| Hole Size | .006” drilled/plated and .008” drilled/not plated typical | .004” laser drilled/plated non-typical |
| Copper Thickness | ¼ oz, ½ oz, 1 oz, 2 oz typical | 7.8 mil & 10 mil non‐typical |
| Material thickness | 1 mil, 2 mil typical | 3 mil and 5 mil non‐typical |
| FR4 Stiffener Thickness | .010” ‐ .125” | |
| Polyimide Stiffener thickness | .002” ‐ .010” | |
Design Considerations for Flexible Circuit Assemblies
Assembling flexible circuits is more complex compared to rigid circuit assembly processes. Correct placement of components is critical to maintaining circuit integrity and functionality once the assembly is in the product. Though our engineers conduct a thorough Design for Manufacturability (DFM) Assessment and provide recommendations to remedy potential design issues, there are certain specifications that you should review internally before submitting your design to our team.
Component Positioning
Components can be mounted to one or both sides of the circuit and must be positioned at least one tenth of an inch from the bend areas. Also avoid placing components near the edges of the circuit.
Solder Joints
We strongly recommend adding teardrops to the junction where the trace meets the lead or pad. As the circuit flexes, the teardrop protects the solder joint by relieving mechanical stress, reducing the chance of the joint breaking.
Stiffeners
Localized, repetitive flexing of the flex circuit assembly can weaken or damage solder joints and affect functionality. All high-stress areas such as those connecting to a button or switch should have a stiffener for added robustness and to protect solder joints from damage.
Industries Served
Exceeding PCB Manufacturer Expectations Since 2008
Tramonto Circuits is ISO 9001:2015 Certified and performs rigorous quality checks during production. Our diligence has resulted in consistent quality and low return rates, assuring that PCB orders comply with IPC Class I, II, or III specifications.
On-Time Delivery
Quality Ratio
24-Hour Quotations
Some of Our Happy Customers
A Manufacturing Process and Communication You Can Trust
Never worry about your project status again. Our collaborative and responsive engineering team keeps you informed every step of the way.
Order Submission and Acknowledgement
Submit your Gerber files, bill of materials, and desired quantity. We provide a response within 24 hours of receipt.
Design Review
Engineers conduct a DFM assessment of your design. If issues are identified, we contact you to discuss recommendations.
Timeline and Delivery Conformation
Receive a delivery date two days after design approval. We have a 98.15% success rate for on-time delivery.
Production and Shipping
Your circuits are fabricated, tested, and assembled in-house at our USA facility. Orders ship via UPS or FedEx.
Frequently Asked Questions
Flexible circuit assemblies are the best option for applications where the assembly must fit into a compact space or when you want to reduce using cables or multiple circuits. The design is highly versatile and flex circuits are frequently used in medical, aerospace, transportation, and consumer product markets.
Our engineers work from your printed circuit board design and offer solutions to develop an assembly, whether that is the addition of a heater or a flexible circuit. Further customizations are available to help integrate your design into cutting-edge technology.
Adding a rigid or semi-rigid stiffener to your flex circuit assembly is beneficial in product designs with high-stress points such as switches or buttons. The additional robustness protects delicate solder joints from damage as the circuit flexes, and is recommended for assemblies placed in keyboards, handheld medical devices, and similar products.
In most cases, we can create new Gerber files from single-layer or double-layer flex circuits that you send to our office. The new file must have your approval before production begins.
