ApplePCB provides a comprehensive range of flexible PCB assembly services. Our advanced PCB assembly facility in Shenzhen, China, enables us to provide design engineers with high-quality services and high-level customer satisfaction.

Flexible PCBs are essential components in modern electronics, particularly for devices requiring weight reduction and efficient use of three-dimensional space. They are widely used in various industries, including consumer electronics, medical devices, industrial equipment, aerospace, military, and transportation.

Flex PCB Assembly Process

The process of assembling flex PCBs encompasses several crucial steps, which you should follow meticulously from beginning to end:

1. Bill of Materials for Flex PCB

Initially, you need to prepare a document known as the bill of materials (BOM), which lists all components to be used in the assembly. This document specifies part numbers, reference designators, and the required quantities of each component.

2. Baking the Flex PCB

Before assembly, the flexible PCB must undergo a baking process to eliminate moisture, especially since it contains humidity-sensitive elements. The PCB is heated to approximately 120°C, with the duration depending on its size and thickness to ensure optimal dryness.

3. Applying Solder Paste

Following drying, solder paste application is the next step. You apply this paste to the board using a stencil that outlines where the solder should go, ensuring a precise application that facilitates component mounting.

4. Mounting Components on the PCB

In this phase, you either manually or automatically place components onto the PCB. The process involves ensuring each component is correctly positioned, utilizing either surface-mount technology (SMT) or through-hole technology (THT) depending on the component size and board design.

5. Soldering Components

With all parts in place, the soldering process, known as re-flow soldering, begins. This step involves heating the board to melt the solder paste, thereby forming secure electrical connections between the board and its components, without overheating or damaging them.

6. Inspecting and Testing the Assembly

To verify the board's functionality and adherence to quality standards, thorough inspection and testing are conducted. This includes checking for physical defects and ensuring all electrical parameters are met, typically using AOI or manual checks.

7. Packaging the Flex PCB

Finally, the assembled flex PCB is carefully packaged, ensuring it is well-protected for transport. This packaging process includes wrapping, labeling, and boxing the board to ensure it reaches its destination safely and is easily traceable.

Characteristics of Flex Board Assembly

Flex board assembly presents unique challenges compared to rigid PCB assembly.

Use of Auxiliary Fixtures

Due to their thin and lightweight nature, flex boards require additional support during assembly. Rigid carriers ensure proper positioning and consistency, while various auxiliary fixtures are employed throughout the process, including trays for carrying, baking, electrical testing, functional testing, and cutting.

Component Density

Compared to rigid boards, flex PCBs accommodate fewer components. This lower density is a crucial factor to consider when designing your board.

Stringent Quality Standards

Flex boards often find application in situations requiring repeated flexing. Consequently, the components and solder joints must meet rigorous standards for cleanliness and reliability to withstand demanding operating conditions.

Cost and Time Investment

Flex assembly typically involves higher costs and longer production times compared to rigid PCB assembly. This is due to the need for additional equipment, personnel, and a meticulously controlled manufacturing environment.

Flex PCB Assembly Service

ApplePCB provides comprehensive Flex PCB assembly services, encompassing fabrication for 1-12 layer boards and component sourcing, with no minimum order quantity or limitations on shape or size. We are capable of completing quick turnaround projects, catering to both prototype and volume production needs for companies across the globe.

Understanding the unique challenges associated with Flex PCBs, particularly their thinness and flexibility, we utilize specialized carriers and fixtures to ensure secure placement and precise soldering during assembly. Leveraging our extensive experience in Flex PCB fabrication and assembly, we identify the most efficient and cost-effective methods to deliver high-quality results for your specific project.

Whether you require prototypes for testing or full-scale production runs, our team is dedicated to providing personalized solutions and exceeding your expectations.

Why Entrust ApplePCB with Your Assembly Needs?

When you choose ApplePCB for your assembly needs, you benefit from two key advantages: our expertise in reflow soldering of Flexible Printed Circuits (FPCs) and our comprehensive inspection, testing, and sub-board capabilities.

Reflow Soldering of FPCs

We utilize advanced forced hot air convection infrared reflow ovens to solder FPCs. This technology ensures even heat distribution across the FPC, minimizing soldering defects. Compared to traditional single-sided tape fixation, our reflow soldering process significantly reduces the risk of FPC deformation, preventing issues like poor soldering, voids, and solder bridges. By meticulously testing and setting precise temperature curves, we optimize soldering quality and enhance overall production efficiency.

Inspection, Testing, and Sub-board of FPCs

Following reflow soldering, we implement a rigorous inspection, testing, and sub-board process for FPCs. Cooling fans at the furnace outlet expedite the temperature reduction of FPCs and carrier boards. Our operators, equipped with heat-insulating gloves, safely handle the high-temperature carrier boards. We then carefully remove the soldered FPCs and visually inspect them under magnification, focusing on identifying potential issues such as residual adhesive, discoloration, tin dip on gold fingers, solder beads, empty solder joints, and solder bridges.

Beyond visual inspections, we utilize specialized test fixtures to perform In-Circuit Testing (ICT) and Functional Circuit Testing (FCT) on all FPCs. This comprehensive approach guarantees the quality and functionality of your FPCs.

With extensive expertise and experience in both FPC reflow soldering and comprehensive inspection, testing, and sub-board processes, ApplePCB is your ideal partner for all your assembly needs.