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D R I V I N G I N N OVAT I O N Mechanical and Optical Processes During Rigid- flex Production by Kur t Palmer, S chmoll America Rigid-flex printed circuit boards are a highly effec- tive solution for placing complex circuitry in tight, three-dimensional spaces. They are now indis- pensable across a range of industries, from medi- cal devices and aerospace to advanced consumer electronics, helping designers make the most effi- cient use of available space. However, their unique construction—combining rigid and flexible mate- rials—presents a fundamental challenge for PCB manufacturers. The mix of materials creates a host of complications for mechanical and optical pro- cesses, requiring a unique blend of expertise and specialized machinery. This article explores how these material combinations influence critical man- ufacturing processes and the specific technologies that are helping process engineers successfully produce these advanced boards. Alignment The most critical topic in rigid-flex production is alignment. Getting the registration right is a two- step challenge that begins before lamination. A s i x- st at i o n m a c h i n e w i t h i n d i v i d u a l st at i o n s a n d C C D c a m e ra s at e a c h st at i o n fo r i n d i v i d u a l c o m p e n s at i o n s . ▼ 28