Technology Comparison

Rigid-Flex vs Flex PCB: Which Technology Fits Your Design?

Both technologies offer flexibility, but rigid-flex adds structural support and component mounting areas. Learn when each approach makes sense.

Quick Decision Guide

Pure flex PCBs are ideal for simple interconnects, dynamic flexing, and space-constrained designs without complex circuitry. Rigid-flex combines the benefits of both worlds: flexible sections for bending and rigid sections for component mounting. Choose rigid-flex when you need to eliminate connectors between boards or require complex circuits in a folding form factor.

Best Choice

Application Dependent

Technology Comparison

Characteristic
Rigid-Flex PCB
Pure Flex PCB
Component Mounting
Excellent (rigid areas)
Limited (needs stiffeners)
Connector Elimination
Max Layer Count
20+ layers
10+ layers
Unit Cost
Higher
Lower
System Cost
Often lower
May need connectors
Design Complexity
Higher
Lower
Flexibility
Flex sections only
Entire circuit
Structural Support
Built-in
Requires stiffeners
Assembly
Single assembly
May need sub-assembly
Reliability
Very high
High
Lead Time
Longer
Shorter
Manufacturing Complexity
Complex
Moderate

When to Choose Rigid-Flex

Rigid-flex excels when you need to combine circuit complexity with mechanical flexibility. It's often the best choice when the alternative is multiple PCBs connected with cables or connectors.

  • Replacing multiple PCBs + connectors with one board
  • Complex circuits that must fold into 3D shapes
  • High-reliability applications (aerospace, medical)
  • High-density component mounting with flex interconnects
  • Applications requiring controlled impedance throughout
  • Designs where connector failure is unacceptable
  • Volume production where assembly savings offset board cost

When to Choose Pure Flex

Pure flex PCBs are the right choice for simpler applications, especially when maximum flexibility or lowest board cost is the priority.

  • Simple point-to-point interconnects
  • Dynamic flex with continuous movement
  • Cost-sensitive applications
  • Thin, lightweight requirements
  • Designs where stiffeners provide adequate support
  • Lower volume productions
  • Applications with standard connector interfaces

Total Cost Analysis

While rigid-flex boards cost more than pure flex, total system cost often favors rigid-flex by eliminating connectors, cables, and assembly steps.

  • Rigid-flex board: 2-5x flex board cost
  • Connector savings: $0.50-$10+ per connection eliminated
  • Assembly labor savings: 30-50% reduction possible
  • Reliability improvement: Lower warranty costs
  • Space savings: May enable smaller enclosures
  • Break-even: Often at 100-500 unit volumes

Reliability Comparison

Both technologies are highly reliable when properly designed. Rigid-flex eliminates connector failure points, while pure flex avoids the complex transitions between rigid and flex sections.

  • Rigid-flex: No connector failures possible
  • Rigid-flex: Careful transition zone design critical
  • Pure flex: Simpler construction = fewer failure modes
  • Pure flex: Connector reliability becomes a factor
  • Both: Proper bend radius design essential
  • Both: Material selection impacts reliability

Expert Technology Selection

Both Technologies

We manufacture both flex and rigid-flex, so recommendations are based purely on your needs.

Cost Analysis

We help calculate total system cost to determine which technology offers best value.

Design Optimization

Our engineers can often simplify rigid-flex designs to reduce cost while maintaining performance.

High Layer Counts

Rigid-flex capabilities up to 20 layers for the most complex applications.

Transition Expertise

Critical rigid-to-flex transition zones designed for maximum reliability.

Prototype to Production

Consistent quality from early prototypes through high-volume manufacturing.

Frequently Asked Questions

Can I convert my flex design to rigid-flex later?

Yes, but it requires redesign. The good news is that rigid-flex often simplifies the overall system design by eliminating connectors. Our engineers can help evaluate the conversion.

Is rigid-flex always more expensive than flex + connectors?

Not always at the system level. While the bare board costs more, connector elimination, reduced assembly labor, and improved reliability often result in lower total cost, especially at volume.

Can rigid-flex sections be as flexible as pure flex?

The flex sections in rigid-flex can match pure flex flexibility. However, bend areas should be designed with 1-2 layers for optimal flex performance.

What's the minimum order for rigid-flex?

We have no minimum order quantity. We produce rigid-flex prototypes in quantities as low as 1-5 pieces.

How long does rigid-flex take compared to flex?

Rigid-flex typically adds 3-5 days to lead time due to additional processing steps. Quick-turn rigid-flex prototypes are available in 7-10 days.

Not Sure Which Technology Is Right?

Our engineers analyze your requirements and recommend the optimal approach. Get expert guidance on flex vs rigid-flex for your specific application.