If you want to understand why flexible PCBs are so much more expensive than rigid PCBs, follow Flex Plus to find out. (Although the actual price will vary depending on factors such as suppliers, materials, design complexity, and production quantity, it can be compared from some typical cost structures and proportions). The difference in cost between flexible PCBs and rigid PCBs is mainly due to the following reasons:
1. Material cost of flexible PCBs and Rigid PCBs
flexible PCBs use different materials from PCBs. They mainly use flexible materials such as polyimide (PI) or polyester (PET). These materials themselves have high heat resistance, good insulation, and flexibility, but their cost is relatively high. In addition, flexible PCBs often use high-precision copper foil as well as special adhesives and cover films, which also increase manufacturing costs.
Flexible printed circuit board materials:
PI or PET, the cost per square meter of such materials is usually $30-50 or more. The use of materials such as copper foil layers, cover films, and glue is large, especially for high-density and multi-layer flexible PCB, the material cost may account for 30%-50%.
Rigid PCB materials:
The PCB circuit board substrate is usually FR4 (epoxy resin and glass fiber). It costs about $10-15 per square meter. That's much less than the flexible circuit board's substrate.
For multi-layer PCBs, the material cost accounts for about 20%-30%.
2. Complex manufacturing process
Flexible PCBs are harder to make than rigid ones. Their process is more complex and needs higher precision. Their flexibility requires avoiding too much stretching or folding during production. This prevents damage to the circuit. It makes the process less tolerant. This increases the scrap rate and costs. Also, flexible printed circuits usually have multi-layer structures and delicate layouts. They need more advanced equipment and technology. In general, the production process cost of flexible PCBs is about 30%-40% higher than that of rigid printed circuit boards.
Flexible printed circuit board manufacturing process:
The production process of flexible PCBs has a low tolerance. It is especially sensitive when handling thin films and flexible materials. This can cause alignment errors or damage. As a result, the scrap rate is high. The process of making flexible printed circuits is complex. It requires high precision, especially when laminating cover films and processing multi-layer circuits. These processes increase production time and cost. The scrap rate of flexible circuit boards may reach 3%–5%, and some highly complex designs are even higher.
Rigid PCB manufacturing process:
PCB manufacturing is mature and has a standard process flow. Multi-layer PCBs are complex to make. But, they cost less to manufacture. The material's rigid structure and easy processing control make it so. The scrap rate during the production process is relatively low, generally around 1%–2%.
3. Large equipment investments
Equipment for making flexible printed circuits is usually costlier than that for rigid PCBs. Flex PCBs are flexible and easy to deform. In production, we need special equipment to handle them. It will avoid damaging the circuits.
Flexible printed circuit board equipment:
Due to the high cost of special equipment used in the production of flexible PCB (such as laser cutting and laminating equipment). To handle flexible materials, the equipment must be more precise. The production line needs regular maintenance. Also, the equipment costs more.
For example, the cost of laser-cutting equipment and automatic optical inspection (AOI) is about 30%–50% higher than that of the equipment used in rigid PCB production.
Rigid PCB equipment:
Rigid PCB manufacturing equipment is conventional. It has mature technology and a low investment.
4. Low production and customization.
flexible PCBs are usually used in high-end electronic devices or customized products. These products usually have high requirements for flexible PCB, such as small size, lightweight, and good bending resistance, so customized designs are usually adopted. The production scale of customized products is usually small, and the output is low, but the design and process complexity are high, so the cost is higher.
Flexible printed circuit board:
flexible PCBs are more used in customized or complex devices such as smartphones and wearable devices, and the batch size is relatively small, resulting in a higher unit cost. Especially for small batch customization, the price is often 2-3 times that of rigid PCB. The price of a small batch of flex PCB maybe $5-10 per piece, while the price may be reduced to $1-3 per piece in large-scale production.
Rigid PCB:
Rigid PCBs are widely used in making large-scale electronics. Mass production greatly reduces their price. The cost of each rigid PCB produced in large quantities may be around $0.5-1.
5. Labor time cost
Flexible PCBs must withstand frequent bending, twisting, or folding. So, they need strict quality inspections before leaving the factory. These include bending, temperature resistance, and electrical performance tests. But, these inspections increase time and cost.
Flexible printed circuit board production:
Due to the complex process, more manual operations and strict monitoring are required during the production process, especially in the stacking and bending area processing of multi-layer flexible PCB. This makes flexible PCBs take longer to produce than rigid ones. Their manufacturing process is more time-consuming. In comparison, the labor and time costs of flexible printed circuit board production lines are about 20%-30% higher on average.
Rigid PCB production:
The production process of rigid PCBs is relatively automated, with relatively fewer manual operations and relatively shorter production time.
6. High R&D costs
Flexible PCBs are often used in high-tech fields. So, manufacturers must invest heavily in R&D to improve materials and processes. For example, flexible PCBs must last long without breaking or degrading. This demands high design and material innovation. The cost of R&D is spread over the product, which also increases the final price.
7. Market demand and supply chain
The demand for flexible PCBs in major fields is rising. These include consumer electronics, automobiles, and medical devices. But, few factories can make high-precision flexible PCBs. So, the supply is limited. This imbalance between supply and demand has also driven up the price of flexible PCBs.
Summary
From the above specific data, it can be seen that the factors that make the production and sales costs of flexible PCBs relatively high include material costs, complexity of manufacturing processes, and high investment in special equipment. The specific price difference varies depending on the complexity of the product, production batch, and market demand, but generally, the price of flexible PCBs is 2-5 times that of rigid PCBs, and even higher in some high-end applications.
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