Trouble in Your Tank: Metallizing Flexible Circuit Materials—Mitigating Deposit Stress
It’s Only Common Sense: Sales as a Team Sport
Dan’s Biz Bookshelf: ‘In Defense of a Liberal Education’
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
"The I-Connect007 team is outstanding—kind, responsive, and a true marketing partner. Their design team created fresh, eye-catching ads, and their editorial support polished our content to let our brand shine. Thank you all! "
Sweeney Ng - CEE PCBSuggested Items
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.
Statement from the Global Electronics Association on the July 2025 Tariff on Copper Foil and Electronics-Grade Copper Inputs
07/31/2025 | Global Electronics AssociationWe are disappointed by today’s decision to impose a 50% tariff on imported copper foil and other essential materials critical to electronics manufacturing in the United States.
Direct Metallization: A Sustainable Shift in PCB Fabrication
07/31/2025 | Jim Watkowski, Harry Yang, and Mark Edwards, MacDermid Alpha Electronics SolutionsThe global electronics industry is undergoing a significant transformation, driven by the need for more resilient supply chains and environmentally sustainable manufacturing practices. Printed circuit boards (PCBs), the backbone of interconnection for electronic devices, are at the center of this shift. Traditionally, PCB fabrication has relied heavily on electroless copper, a process that, while effective, is resource-intensive and environmentally hazardous. In response, many manufacturers are turning to direct metallization technologies as a cleaner, more efficient alternative.
Considering the Future of Impending Copper Tariffs
07/30/2025 | I-Connect007 Editorial TeamThe Global Electronics Association is alerting industry members that a potential 50% tariff on copper could hit U.S. electronics manufacturers where it hurts.
WellPCB, OurPCB Launch Low-Cost PCB Assembly and Custom Cable Assembly Solutions
05/29/2025 | ACCESSWIREWellPCB and OurPCB, world leading PCB manufacturing service providers, announced today that they have officially launched new Low-Cost PCB Assembly Solutions and Custom Cable Assembly services to meet the needs of the electronics manufacturing industry for high cost performance and flexible customization.