Driving Innovation: Mechanical and Optical Processes During Rigid-flex Production
It’s Only Common Sense: Your Biggest Competitor Is Complacency
The Chemical Connection: Onshoring PCB Production—Daunting but Certainly Possible
Flex Time: Why is Rigid-Flex So Expensive?
July 11, 2018 | Bob Burns, PRINTED CIRCUITSEstimated reading time: 1 minute
One question that I hear fairly often, particularly after an initial quotation, is “Why is rigid-flex so expensive?” In this article, I’ll share with you the cost drivers in rigid-flex relative to standard rigid boards and flex circuits with stiffeners. A typical rigid-flex PWB will cost about seven times the cost of the same design on a hard board, and two to three times an equivalent flex circuit with stiffeners. A good way to estimate the cost of rigid-flex board in low-level production quantities is 35 to 40 cents per square inch, per layer. So, if you have an eightlayer board that measures 4” x 6”, your costing would look like this:
8 layers x 4” x 6” x $0.40/sq.in. = $ 76.80 each
Again, this applies only to low level production quantities. This is a helpful calculation for getting a quick, rough idea of what your part might cost as a rigid-flex. Rigid-flex PWBs cost quite a bit more, primarily because of the higher cost of the raw materials we use to build them, relative to standard rigid boards or even flex boards. The number one cost driver is the no-flow prepreg. Rigid-flex manufacturers have to use no-flow, or sometimes low-flow prepreg, so that the resin does not flow out onto the flexible areas of the board. No-flow prepregs are designed to offer just enough flow to fill the circuits in the hardboard areas, but not enough to flow out onto the flexible areas of the boards.
No-flow and low-flow prepregs run from $1.50 to $3 per square foot. Conventional rigid board high-flow prepregs run around $.25 per square foot, so there is a large differential in price just for the prepreg. A couple of other things contribute to the cost as well. No-flow prepreg is only available in 1080 and 106 glass cloth styles, which typically press out at .0025” and .002” respectively, so they are thin. Rigid-flex manufacturers don’t have 2113, 2116, 7628 glass styles available to manufacture your board. It is wise to use two plies of prepreg between layers within your construction. The no-flow resin resists flowing, so to assure adequate fill, we use two plies of prepreg between each layer.
To read the full version of this article which appeared in the April 2018 issue of Flex007 Magazine, click here.
Share on:
Testimonial
"Your magazines are a great platform for people to exchange knowledge. Thank you for the work that you do."
Simon Khesin - Schmoll MaschinenSuggested Items
Defense Speak Interpreted: The Autonomous Plane Battle—Skyborg Vs. Loyal Wingman
10/07/2025 | Dennis Fritz -- Column: Defense Speak InterpretedI’m awaiting the updates for the U.S. Air Force's Skyborg and Loyal Wingman airborne driverless vehicles. As the hype of self-driving cars has given way to more mundane autonomous activities, so too has the hype of uncrewed planes given way to reality. In cars, the SAE International association classifies degrees of autonomy from 0 to 5, as do some defense aerospace applications of unmanned flight, which have been reduced to practice, while others remain under development.
Schweizer Ends Staff Restructuring Measures and Short-Time Working at the Schramberg Site
10/01/2025 | Schweizer Electronic AGSchweizer Electronic AG has implemented comprehensive measures to adjust its cost and personnel structure at its Schramberg site due to strong market fluctuations in the automotive and industrial electronics sector. Thanks to the successful restructuring, short-time working can now be ended with immediate effect. A stable order situation is expected for the fourth quarter, with signs of growth momentum returning in 2026.
Global Sourcing Spotlight: Finding the Balance Between Cost and Quality
09/24/2025 | Bob Duke -- Column: Global Sourcing SpotlightIn global sourcing, pursuing lower costs often takes center stage. It’s the shiny lure that gets buyers to cast their lines into unfamiliar waters. But seasoned professionals know that in the long run, sourcing is less about price tags and more about value. The real magic—and margin—lies in finding the balance between cost and quality.
I-Connect007 Editor’s Choice: Five Must-Reads for the Week
08/15/2025 | Marcy LaRont, I-Connect007In our industry, my top reads include Prashant Patel’s overview and argument for reshoring, which I found to be a great general overview and breakdown. In further support of the onshoring/reshoring message, I’m highlighting Nolan Johnson’s interview on the survey and report by the Reshoring Initiative. Check out my interview with USPAE’s Jim Will on the state of the flat panel display (FPD) industry and the risks associated with it for U.S. defense and critical infrastructure products.
Global Electronics Industry Remains Under Pressure from Rising Costs
08/04/2025 | Global Electronics AssociationThe global electronics manufacturing supply chain remains under pressure from rising costs, with 61% of firms reporting higher material costs and 54% noting increased labor expenses. according to the Global Electronics Association’s Sentiment of the Global Electronics Manufacturing Supply Chain Report.