Expand the lifetime of your electronic device using flex pcb

By | Date posted: | Last updated: December 11, 2025
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There would be very few takers wanting to build a device to fit the circuit board; most would prefer to design circuitry to fit the device. This is the exact reason why flex and rigid flex circuits are gaining increasing acceptance. They offer multiple advantages both in terms of a new project or even if you want to re-engineer an old one.

Flex PCBs find application in a number of electronic devices, hard disc drives and desktop printers. They are also used extensively in the following industries:

  • Communications
  • Consumer Electronics
  • Automotive
  • Medical
  • Aerospace
  • Military
  • Transportation

Even though they are not a new invention, they are increasingly being used for their versatility in design. They are known to unlock both functional advantages as well as cost savings for manufacturers.

Here are some of the key advantages of using flex PCB:

Reliability and increased life span of your electronic device

With both flex and rigid-flex PCB, the number of interconnections required are significantly reduced. What this in turn means is that there are fewer solder joints, contact crimps as well as connectors. Fewer interconnectors means that there are fewer sources of failure and hence greater reliability and increased life span of the device. The flexbility of the circuit also works towards improving shock performance.

flexbility in packaging

A Flexible PCB Board ensures that there is space saving as also more efficient use of space. What this means is that multiple circuit boards, connectors etc. can be replaced with a single unit. Typically it is seen that flex designs occupy 10% of the weight and space occupied by wired solutions. Fewer parts also create less supply chain risk as well as reduced maintenance requirement.

Improved Capability

 Flex systems are known for their superior performance. They accept any component or connector that works with a rigid PCB, besides working with direct solders, crimped contacts and the like. Besides, flexble circuits are not impacted by harsh environments, including high temperatures. They are also resistant when it comes to exposure to chemicals, radiations and UV.

Cost Efficient

 With lower material requirements, what a flexble circuit board also ensures is lower shipment costs. Also with fewer parts and simple installation the assembly costs are lower. Also with increased reliability comes cost saving on account of longer lasting products.

Also checkout: Flex Printed Circuit Board Cost

Precautions in using Flex PCBs

While a flexble printed circuit comes with a whole lot of advantages, it is important to keep some precautions in mind so that the circuit functions reliably.

There are some features that a rigid PCB can incorporate that a flex PCB must avoid. Primary among them being those that cause discontinuity in the bent areas. A via placed in the bent zone, for example can cause discontinuity. Additionally, conductor width or direction must not be changed in the bent area. An optimum flex-circuit design maintains a uniform width for all conductors. Also, a change in the direction of the conductor in the bend area needs to be avoided.

It is also important not to stack conductors on multiple layer boards. It is also prudent to not have sharp inside corners on the circuit outline as it can cause tears.

Some other areas to pay attention to include the fact that heat should not overstress the circuit. A heat gun can produce high enough temperatures to blister a circuit and hence its use should be avoided. Also, rigid temperature profiles need to be avoided when it comes to reflow flex PCBs.

Wide conductors are known to tolerate bending more than small ones so it is a good idea to widen small conductors in the bend area, even though the widening should be gradual. Also flex circuits with multiple layers are thicker. Often times though the combination of deep plated barrels with the added thickness leads to issues. It is therefore advisable to place vias in areas that have little or no bending or at least in areas that have least amount of bending.

As a standard practice it is also good to place fillets on via pads. They tend to eliminate stress points that have the potential of resulting in cracks.

It is also advisable to consult the Rigid flex PCB manufacturer during the design phase itself as that can lead to finding the most efficient solution that will work for your unique design.  With modern software programs complex 3D designs can be accommodated thereby allowing engineers to stack and test flex parts in layers. This in turn reduces the time and costs associated with testing. Modern 3D modeling software helps developers as well as fabricators to align their expectations as also to speed up the entire process.

With the above precautions in place you will be able to use your flex PCB to numerous advantages including giving your electronic products a whole new lease of life.

At Technotronix, we are fully equipped to handle your PCB manufacturing requirements. With over 4 decades of experience in rigid-flex PCB manufacturing as well as assembling PCBs with differing levels of complexities, our team of experts and state-of-the-art equipment ensures that all our PCBs meet the industry standards of quality and testing. In case if you have any questions, please feel free to contact us via email at [email protected].

PCB Conformal Coating vs PCB Encapsulation – Which one would you Choose?

By | Date posted: | Last updated: December 11, 2025
PCB Encapsulation

With the rapid growth in the electronics industry, the use of PCB is also growing exponentially. Its use in different applications however means that the PCB is subject to different environmental conditions. In places where the PCB is subject to moisture or harsh chemicals, performance can be of concern. It is therefore imperative that the PCB be coated to protect it from environmental conditions. This protection can be offered by way of either conformal coating or potting or by way of encapsulation.

Properties of PCB Potting and PCB Encapsulation:

Potting as well as encapsulation resins go a long way in offering a high level of protection for the PCB. In fact, encapsulation offers both electrical properties as well as mechanical protection. This high level of protection is ensured by way of a mass of resin surrounding the entire unit. This is far more substantial when compared to conformal coating. In fact, potting along with encapsulation offer fool proof protection. However potting and encapsulation resins need to be tested in a number of environments, so that their specifications and suitability for use can be determined. These tests typically involve exposing them to controlled atmospheric conditions over a period of time. The dimensions, weight and appearance of the resin is seen before and after the tests to check if any changes have occurred.

Properties of conformal coating PCB:

Besides potting and encapsulation resins, conformal coating can also be done in order to protect the PCB. This is done by applying it as a thin film. Since the film takes to the contours of the board, it does not cause any dimensional changes or add to the weight significantly. This in fact acts as a big advantage in favour of conformal coating as it lends itself easily to portability of the device. Tests, however, need to be conducted to evaluate the electrical and mechanical performance of the film in the applicable environment. The film needs to be tested in conditions such as humidity, temperature and more in order to determine the suitability of the film in such atmospheric conditions. Check out the guide on how Conformal Coating becoming a core driver to PCB Fabrication.

Application area of conformal coating & PCB potting

Both Conformal Coating as well as encapsulation and potting are available in different variants that make them suitable for particular applications. For standard conditions most, conformal coatings as well as potting and resin encapsulation work well. However, if the conditions are harsh, the choice of coating will vary. For example, acrylic coating works well in conditions where there is sustained exposure to UV light. However acrylic coating may not work well in conditions where the humidity levels are high. In such conditions, a Non-VOC Coating would work far better.

In cases where there is likely to be a lot of mechanical stress or where environmental conditions are harsh, optimum performance of the device will be obtained through the use of potting and encapsulation resins. Silicon resins or polyurethane resins are known to offer a greater degree of flexibility. In fact, polyurethane resins are preferred where temperatures are particularly low. They are also ideal for conditions where the device is immersed in water. Epoxy resins are preferable where exposure to chemicals is high.

Final words on Conformal coating vs potting:

Clearly therefore the choice of coating has a lot to do with the physical environment in which the device operates. While conformal coating scores on parameters such as ease and speed of processing, potting and encapsulation resins are preferable where climatic conditions are harsh. Conformal coating is also preferable where miniaturisation and portability of the device is essential. With both offering their distinct advantages, it is essential therefore to conduct a thorough evaluation of your unique requirements before coming at a decision with regard to the coating.

Technotronix is a skilled and experienced professional in providing apt PCB layout and PCB fabrication service. Our strong team of researchers and technical experts have made it possible to provide an effective lamination solution for your PCB project. Be it high frequency laminates, shrinking hole to hole pitch, exotic vias structures, multiple lamination cycle, lead free or halogen free solder assembly with strict environmental security considerations and high operating temperature are some of the highlights to our tough laminate technology implementation. You can drop an email to [email protected] or give us a call at 714/630-9200 to solve your queries or to get a quote.

The effects of ESD (Electrostatic discharge) on PCBs

By | Date posted: | Last updated: December 11, 2025
PCB Manufacturing

What is ESD?

Electrostatic Discharge or ESD as it is commonly called, occurs when two objects with different charges come close, so that the dielectric between them is broken. The common form of ESD that all of us are familiar with is lightning. Ever so often we could feel little sparks from a wool blanket, for example, which is once again a result of ESD.

How does ESD affect PCB?

When a PCB comes close to any object that has an opposite charge, it is subject to ESD. If the two come in contact, voltage is discharged and a massive voltage spike is created. Once the spike dissipates, electromagnetic fields are generated. It is therefore important to minimize the effect of the discharge. This is typically referred to as an PCB ESD Protection.

With modern chipsets having little tolerance for high voltage, an ESD event can as much as totally ruin the IC. The impact of ESD needs to therefore be factored in the design process of the PCB, as later it could lead to a host of redesigning to fix issues.

ESD can exist in many forms. While it typically requires several thousand volts for ESD to be felt by a person, even a small discharge can ruin semiconductors if the part is in the path of the ESD.
In turn this damage can be latent or catastrophic.

Catastrophic Damage:

This refers to the permanent damage to the device’s circuitry and can be detected using a performance test.

Latent damage:

This is said to occur when a device is partly degraded on account of being exposed to ESD yet continues to run even though its lifetime behavior is likely to be affected making the device unreliable.

Costly Effects Of ESD

While a catastrophic failure can be detected at an early manufacturing stage, it may not turn out to be as costly as a latent damage since it isn’t normally detected easily. As the product passes the regular inspection, latent failures can prove to be extremely costly besides impacting the company’s reputation.

What causes ESD?

ESD can be caused by a number of seemingly ordinary activities. A simple activity such as plugging in a cable can lead to a discharge. It is therefore important to protect your PCB from external connections as plugging in or pulling out a cable can expose the devise to the risk of ESD. There are, therefore, a number of precautions that can be taken to protect your PCB from the risk of ESD. Common precautions include:

  • Using a copper land or pad to attach connectors
  • Keep the pad separate from the PCB ground
  • Use a Transient Voltage Suppressor to protect the board

It is also prudent to establish and identify an ESD Protected Area, which is a clearly demarcated space within which all surfaces, objects, people and ESD Sensitive Devices (ESDs) are kept at the same potential. Typically all surfaces are linked to the ground. The area also needs to be identified with a clear signage and should allow access to only trained personnel. Periodic checks of installed products are mandatory within the area while all non-essential insulators need to be removed. It is also important to identify ESD Sensitive items as also to provide adequate ESD Control training to the staff to ensure that ESD control procedures are followed. The staff needs to be aware of the threat of ESD as also the ways and means of controlling static electricity.

PCB Layout to prevent Electrostatic Discharge

Apart from this, a whole lot of PCB Layout practices can go a long way in protecting PCB. These include:

Remove circuit loops:

Loops can lead to unwanted current. This in turn affects performance as unwanted current spikes can enter any loop. Due care therefore needs to be taken to ensure there are no loops.

Utilize ground plane layers in the printed circuit board:

Using a ground plane within a circuit board can go a long way in helping to reduce loops and therefore unwanted current.

Reduce line lengths:

Reducing line length in effect reduces the radiated energy received and therefore reducing the spikes from electrostatic discharges.

Reduce parasitic inductance:

Protection circuits can only work effectively if parasitic inductance levels are low. In turn parasitic inductance can be reduced by keeping the line lengths short.

Avoid running sensitive tracks near the extremity of the PCB:

The extremities of the board are more likely to pick up static discharge. It is therefore prudent to keep sensitive lines away from the extremities.

With electronic circuitry becoming increasingly smaller, the sensitivity to ESD is on the rise. What therefore also increases is the need for proper ESD protection.

Technotronix offers Electronics Manufacturing Service with combining state-of-the-art technology and advanced engineering to deliver unparalleled quality and service. Our prolonged goal is to serve our customers with electronic telecom solutions for development in telecommunication industry and to create advanced IT applications for our customers globally. To acquaint with Technotronix, reach us at [email protected] to get more information about PCB Manufacturing services for electrical telecom applications or prototypes!

Save Time and Energy by Keeping up with Technology and PCB Manufacturing Trends

By | Date posted: | Last updated: December 11, 2025
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The global market for Printed Circuit Boards or PCBs as they are known as in popular parlance, is growing exponentially. The market is in turn shaped by the growth of the electronics industry in general and by computers, smartphones and tablets in particular. As more and more opportunities arise from the combination of various technologies, the PCB market is slated to grow further. It is only prudent therefore to keep up with new trends in technology as well as in PCB Manufacturing.

Top PCB Industry trends are as below:

Digitalization

With increased digitalization along with the declining costs of data transmission and the growth of “Internet of Things”, it is forecasted that necessary infrastructure will emerge as the strong areas of growth. These include base stations for data transmission, computers, data centers and more. Within the computers segment, servers and storage media show tremendous growth potential

Growth of smartphones

The greatest technological growth drivers in the electronics industry are the smartphones. Not only are they the largest segment of the global electronics industry they are also the fastest growing. On account of the growth of IoT as well as the impending introduction of 5G Networks, the market for communication software is only slated to grow.

Consumer market

The consumer market which has demand for Printed Circuit Boards in products such as cameras, televisions and other smart devices, is currently not showing major growth. However this segment is likely to pick up driven by the growth of 4K TVs, smart watches, handheld projectors and more.

Automotive electronics- driving growth through new devices

As per Prismark report, the share of the automotive market in electronic systems which showed 8.1% decline in value in 2015 is now expected to grow. In fact the growth rates for electronic systems for the automotive market along with the printed circuit boards in this segment are projected to be significantly higher than the average overall figures for the global electronics industry.

The demand in this segment is driven by applications in the area of safety as also by the use of HDI and microvia PCBs. This include segments such as navigation, multimedia and infotainment systems, camera systems and electronic transmission control. The demand is also on account of the growth in the concept of autonomous driving which enables collection of data and information from camera systems, ultrasound sensors etc.

Medical Electronics

The growth in the medical electronic market is driven by the high level of complexity in the market viz diagnostic and imaging devices, therapy application, patient monitoring and more. Growth is also slated on account of application areas such as surgical lighting, analytical instruments and molecular diagnostics with a high degree of medical PCB prototype innovation.

Industrial Electronics

The industrial electronics market is influenced by applications in the area of measurement and control technology, power electronics, lighting systems as well as diagnostic instruments, RFID readers as also railway technology. Going forward, M2M or what is machine-to-machine as well as machine-to-man communication modules driven will drive further growth.
Other than mapping sector wise growth, some of the other trends to watch out for include:

Reshoring

With a host of issues cropping up with off shore suppliers, manufacturing is now seeing a resurgence of US based operations both on account of quality assurance and safety procedures. Reshoring also comes with the added benefits of lower costs as well as better customer support.

Green PCB Manufacturing

Increasingly the benefits of incorporating eco-friendly initiatives in the manufacturing process are becoming more and more evident. It allows for higher efficiency as also positioning the company as a responsible corporate citizen. TechnoTronix delivering innovative renewable energy solution for Green PCB prototype.

Cloud Technologies

With the increased need for cybersecurity, the use of cloud based technologies are on a rise. The cloud provider is in a position to monitor network traffic for any attacks, thereby allowing safe traffic to pass through to the website. These also allow small enterprises to be more competitive as cloud technologies come at a lower cost compared to traditional data storage and maintenance systems.

Artificial Intelligence

Artificial Intelligence or AI which has already made its way into homes is now set to change the industrial workspace and the world of manufacturing. This is not only true of assembly line robots or self driving devices but also areas such as analyzing data sets, market trend evaluations, overall decision making. In fact it is projected that AI alone can boost the manufacturing sector’s gross value added by $4 trillion.

The above are only a few areas that anyone working in the industrial manufacturing space should be aware of, in order to remain ahead of the curve. Preemptive knowledge and action in these areas will go a long way in enhancing productivity.

At Technotronix, we are fully equipped to handle your PCB manufacturing requirements. With over 4 decades of experience in PCB manufacturing as well as assembling PCBs with differing levels of complexities, we follow industry best practices to ensure we deliver cutting-edge products. Our team of experts and state-of-the-art equipment ensures that all our PCBs meet the industry standards of quality and testing. It is our vast portfolio of satisfied clients that stand as the biggest testimony to our success. In case if you have any questions, please feel free to contact us via email at [email protected]