Wearable technology has transformed from novelty to necessity. Smartwatches, fitness trackers, health monitors, and smart clothing are now integral parts of daily life, continuously monitoring our health and keeping us connected.
The success of wearable devices depends heavily on the flexible circuits inside them. These circuits must be thin enough for comfort, flexible enough to conform to body contours, reliable enough for continuous operation, and sophisticated enough to integrate multiple sensors, wireless connectivity, and power management in a tiny package.
Our wearable-focused flex PCB solutions address all these challenges. With ultra-thin constructions as low as 0.05mm, tight bend radius capability, and integration expertise for sensors and wireless modules, we help wearable manufacturers create products that users will actually want to wear.
Total thickness from 0.05mm enables integration in the slimmest wearable designs. Minimal bulk for maximum user comfort.
Tight bend radius down to 0.5mm allows circuits to conform to wrists, heads, and body contours. Dynamic flex capability for joints.
Designed for integration with heart rate (PPG), SpO2, temperature, IMU, and other wearable sensors. Optimized signal routing for accuracy.
Integrated antenna solutions for Bluetooth, NFC, and cellular connectivity. Impedance-matched traces and antenna tuning options.
Flexible circuits enable the full spectrum of wearable technology.
Display interconnects, sensor modules, and main boards all use flex circuits. Multiple flex sections connect different functional areas within the tight watch enclosure.
Heart rate monitors, step counters, and sleep trackers rely on flex circuits for slim profiles and comfortable fit against the skin.
Continuous glucose monitors, ECG patches, and vital sign monitors use flex circuits with biocompatible materials for extended body contact.
True wireless earbuds pack complex functionality into tiny spaces. Flex circuits connect batteries, speakers, microphones, and wireless modules.
E-textiles and smart garments integrate flex circuits that survive washing and stretching. Specialized constructions for fabric integration.
Head-mounted displays use flex circuits to route signals around complex 3D geometries while minimizing weight near the user's face.
Wearable flex design requires careful optimization for size, weight, and user comfort.
Every micron counts in wearables. We help optimize layer count, material selection, and copper weight to achieve minimum thickness while meeting electrical requirements.
Many wearables benefit from rigid-flex construction. Rigid areas support components while flex sections enable folding and body conformance.
Optical sensors require careful pad design and via placement. We optimize layouts for PPG (photoplethysmography) and other optical sensing technologies.
Integrated antenna solutions for BLE, NFC, and cellular. We provide impedance matching and antenna tuning options to maximize wireless range in body-worn devices.
Design for IP67/IP68 ratings includes proper pad spacing, solder mask design, and interface with sealing elements.
Material choice impacts comfort, reliability, and regulatory compliance.
Proven reliability for general wearable applications. Available in ultra-thin constructions with excellent flex performance.
For devices in extended skin contact, we offer materials with biocompatibility certifications suitable for consumer wearables.
Thinner, more flexible construction without adhesive layers. Preferred for the most demanding wearable applications.
Rolled annealed copper provides superior flex fatigue resistance. Essential for circuits in dynamic flex areas like wristbands.
Thin polyimide coverlay minimizes total thickness. Color options (black, white) for aesthetic integration with device design.
4-layer ultra-thin rigid-flex connecting display, sensors, battery, and wireless modules. 0.15mm total thickness in flex regions.
Medical-grade flex circuit with integrated electrochemical sensor interface. Biocompatible materials for 14-day body wear.
Miniaturized flex connecting Bluetooth SoC, audio codec, battery management, and touch controls in each earbud.
Our thinnest single-layer construction is approximately 0.05mm (50 microns). Double-layer designs start around 0.08mm. Thickness depends on copper weight and layer count.
Yes, we offer polyimide and coverlay materials with biocompatibility documentation suitable for consumer wearables. For regulated medical devices, we provide materials supporting your regulatory requirements.
Yes, we design and manufacture flex circuits with integrated antennas for BLE, NFC, cellular, and other wireless protocols. We provide impedance matching and tuning options.
We support prototype quantities from 5 pieces. For wearable development, we recommend starting with prototype quantities for design validation before production commitment.
We use rolled annealed copper, optimize trace routing perpendicular to bend axis, and validate designs with flex life testing. Our designs are proven for millions of flex cycles.
