Rigid-Flex Boards111
FR-4 rigid sections and PI flex sections laminated as one board: no connectors, no mating solder joints, more compact 3D assembly and higher reliability - the premium choice for AR/VR, medical and automotive products.
What is a Rigid-Flex Board
A rigid-flex board laminates rigid FR-4 sections and flexible PI sections into a single board, replacing the "FPC + connector + rigid board" assembly - fewer interconnects mean fewer failure points, making it ideal for products with tight space and demanding bend reliability.
| Structure | FR-4 rigid sections + PI flex sections, laminated as one |
| Stack-up Notation | e.g. 2R+4F+2R (rigid-flex-rigid) |
| Bend-Area Design | Bend radius ≥ 6-10x total flex thickness |
| Common Materials | DuPont PI + FR-4 hybrid stack-up |
| Key Advantage | No connectors, fewer solder joints, 3D assembly |
| Typical Uses | AR/VR, medical wearables, automotive, industrial cameras |
Three Critical Zones of a Rigid-Flex Board
One rigid-flex board = rigid carrier zone + flexible bend zone + reliable transition zone; together they determine the reliability of the whole board.
Rigid Zone
FR-4 laminated area carrying components and pads, supporting high layer counts and impedance control.
Flex Zone
PI film area with no routing inside the bend; copper traces sit on the neutral axis to spread stress.
Transition Zone
Rigid-flex lamination boundary with gradual layer transitions and rounded openings to prevent stress tearing.
Rigid-Flex vs FPC + Connector
Each option fits different scenarios - weigh reliability, space and cost to choose.
FPC + Connector
Traditional- Connectors take up space and add BOM cost
- Mating solder joints are the weak link for reliability
- Best for: low-cost designs that need disassembly
Rigid-Flex
High Reliability- Zero connectors, zero mating solder joints
- Simplified assembly completed in a single SMT pass
- Best for: high-reliability, ultra-compact products
Design Support
Engineer Review- Bend-area keep-out routing and layer-transition design
- Free stack-up review and feasibility analysis
- Start with just Gerber + stack-up table
Product Showcase
Standard Rigid-Flex Cases (4-8 Layers)
6-Layer Medical Probe Rigid-Flex Board
8-Layer Industrial Camera Rigid-Flex Board
4-Layer Sensor Belt Rigid-Flex Board
10-Layer Industrial Touchscreen Rigid-Flex Board
Ultra-Thin / HDI Rigid-Flex Cases
AR Glasses Ultra-Thin Rigid-Flex Board
8-Layer HDI Automotive Radar Rigid-Flex Board
6-Layer TWS Earbud Charging Case Board
6-Layer Medical Endoscope Rigid-Flex Board
Manufacturing Capabilities
Standard manufacturing capability range for this product line. Contact our engineers to evaluate special requirements.
| Total Layers | 4 - 12 layers |
| Flex Layers | 2 - 6 layers |
| Board Thickness | 0.3 - 2.0 mm (tolerance ±10%) |
| Min. Bend Radius | ≥ 6x total flex-area thickness |
| Min. Trace/Space | 3.5/3.5 mil (flex area 4/4 mil) |
| Min. Hole Size | 0.2 mm (plated vias in flex area) |
| Surface Finish | ENIG (standard) |
| Quality Standard | IPC-6013 Class 2 (Class 3 optional) |
Lead Time & Pricing Highlights
One-piece lamination that bends without breaking
Zero Connectors
Eliminates FPC connectors and mating joints, cutting interconnect failure points by more than 50%.
Compact 3D Assembly
Flex sections fold freely to fit irregular spaces and folding structures.
Bend Reliability
Neutral-axis flex design verified against IPC-6013 bend reliability requirements.
Simplified Assembly
The whole board is assembled in one SMT pass - no mating steps or manual labor.
Typical Applications
AR / VR Devices
Ultra-thin rigid-flex links between optics and main boards in compact curved spaces.
Medical Devices
Bend circuits for endoscope probes, hearing aids and body-worn monitors.
Automotive Electronics
Vibration-resistant interconnects for steering-wheel buttons, radar and displays.
Industrial Cameras
Stable flexible connections between lens modules and image sensors.
From Gerber to delivery in four steps
Upload Files
Send Gerber/ODB++ and stack-up table; standard boards get instant pricing.
Review & Quote
Complex boards get an engineer review before quoting.
Confirm Production
Confirm specs and price, pay online, and your boards enter the production queue.
Test & Deliver
Flying probe/fixture testing on every board with reports, shipped worldwide.
Further Reading
For more PCB process knowledge and technical practice, visit our blog center.
