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Are Flex Circuits a commonly accepted electronic component or are they still considered a state-of-the art interconnects?

Flex Circuits have been a viable and widely used interconnect packaging solution for over 30 years and are designed in to everything from consumer products to mission critical weapons systems and space exploration equipment.

We design many PCBs, but we have never attempted a Flex Circuit. Are there many differences and can we get help with the design?

Flex Circuits can be designed in much the same way as PCBs, but there are some critical differences to which the designer must have an appreciation. Vulcan Flex Circuit Corp. provides Flex Circuit design assistance at no charge.

I have heard that Flex Circuits are much more expensive than PCBs?

The raw materials used to make Flex Circuits are - per square foot - more expensive than the same materials used to make PCBs. And the fabrication process is a bit more complex. However, the Flex Circuit, by virtue of its design, will replace either wiring, connectors, other PCBs or a combination thereof - and the labor to put them all together. When this is taken into consideration Flex Circuits are almost always the more economical alternative.

What sort of information do you need to quote my Flex Circuit and then again to fabricate it?

To quote a Flex Circuit we need a drawing or sketch which defines the dimensions of the item, the construction (stack up and material), the number and size of any holes, and any metallization and finishing requirements. We do not need Gerber files to quote. To fabricate the item we will need the Gerber files.

I just need a small prototype run to get started. What are you minimum lot charges and tooling and test charges?

These charges can vary significantly depending upon product complexity and size. Please contact your Vulcan Flex Circuit customer service representative to quickly get a minimum lot charge estimation.

How long will it take to make my Flex Circuits? Can I get them as quickly as PCBs?

As with minimum lot charges this can also vary depending on complexity and part size. At Vulcan Flex Circuits we set aside capacity for very quick turns for our strategic customers.

What if I design a Flex Circuit, have you make it, and then I find out that it doesn't quite fit into my box?

We can't assure that this will not happen, but we do offer a no charge Mock Up service. During the design phase we will take your rough part definition and quickly make a mechanical representation of the item - from the exact materials intended for the final product. With this Mock Up you can test fit and installation in your box as well as demonstrate your design concept to others.

Are Flex Circuits covered under any Mil-Specs?

Flex Circuits and the materials and processes used to make them are covered under a host of DOD and IPC specifications. The primary ones are: IPC-2223 (design); IPC-6013 (fabrication); and MIL-P-50884 (fabrication).

Can I solder components to a Flex Circuits?

Electronic components (through hole and SMT) can be soldered to Flex Circuits in much the same way as PCBs, with a few process differences the Vulcan Flex Circuit engineers can help you with. The most common design approach is to place all components in an area of the Flex Circuit that can be rigidized (a rigid section of a rigid-flex board or a section of a Flex Circuit with a stiffener).

If I design in a Flex Circuit will I be limited to only a few suppliers?

There are many suppliers in North America - and indeed the world - of all types of Flex Circuits. The DOD maintains a Qualified Products List of those companies certified to fabricate Flex Circuits for defense applications (reference QPL-50884).