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64 I-CONNECT007 MAGAZINE I JANUARY 2026 polyimide, polyester, and other thin dielectric films, allowing them to be bent, folded, twisted, and shaped, and even stretched to conform to complex geometries while maintaining reliable electrical connectivity and, perhaps most importantly, perfor- mance. It is worth noting that includes any mate- rial made thin enough, including those traditionally seen as brittle, such as glass and silicon (Figure 2). Now, let's explore their usefulness. First, a reminder of SWaP (Size, Weight, and Power or Performance), which is often used to evaluate or assess a design in terms of target con- cerns for product developers. It is particularly suitable as an overarching guide, allowing one to assess how flexible circuits can help product developers accomplish their objectives. Compactness and Miniaturization One of the most well-established and sought- after advantages of flexible circuits is their ability to reduce the size and weight of electronic prod- ucts. Traditional rigid PCBs often require substan- tial space for connectors, wiring, and component spacing. In contrast, flex circuits allow components to be tightly packed and interconnected in three dimensions, using folded or rolled configurations. This reduces the overall volume of an assembly, enabling thinner and lighter products. In consumer electronics, this property is invalu- able. Smartphones, smartwatches, tablets, and laptops often use many flex circuits to connect displays, batteries, cameras and sensors in increas- ingly compact form factors. In medical devices, par- ticularly those designed to be implantable or wear- able (Figure 3), flexible circuit technology facilitates design and miniaturization of real-time vital sign monitoring and life-saving equipment that must conform to the smooth curvatures and contours of the human body. This is where flexible circuits and their more recently developed "cousins"—stretch- able substrates—truly shine. The space-saving benefits of flexible circuits can translate directly to performance improve- ments, including longer battery life, increased portability, greater versatility, and enhanced or improved user ergonomics. Enhanced Reliability and Mechanical Resilience Flex circuits have long proven their ability to enhance the mechanical reliability of electronic systems by reducing the number of connections, including both reduced number of solder joints and connectors, common design elements that are typ- ically the most failure-prone in traditional assem- blies. Each interconnect in a rigid PCB system is a potential point of mechanical or thermal fail- ure. By replacing bundles of wires and connectors with a single integrated flexible circuit, the system becomes inherently more robust. In high-vibration environments, such as those found in automotive and aerospace systems, flex- ible circuits perform exceptionally well. They can absorb the mechanical stresses of use, mitigate stresses and strains associated with bending, and associated with either shock, vibration, or mechan- ical operation. Moreover, the flexible circuit can maintain consistent electrical performance under harsh environmental conditions. This is particularly beneficial in automotive, military, and aerospace Figure 2: Anything made thin enough can be flexible. This is an example of a thinned device fabricated by American Semiconductor in Boise, Idaho. Figure 3: A flexible and stretchable circuit with integrated RFID for wirelessly monitoring a patient. (Source: Jabil)