IPC International Community magazine an association member publication
Issue link: https://iconnect007.uberflip.com/i/1542698
68 I-CONNECT007 MAGAZINE I JANUARY 2026 ponents can be printed or embedded directly into the cir- cuit. This functional integration reduces part count, saves space, and streamlines manufacturing, all of which can contribute signif- icantly to increased product reli- ability and performance. Thermal Management and Environmental Durability Thermal performance is another area where flexible circuits offer significant advantages. Materi- als like polyimide have excel- lent thermal stability, allowing flex circuits to withstand high- temperature operating environ- ments. Additionally, the thin and spread-out nature of flexible substrates helps dissipate heat more evenly than bulky or con- fined rigid boards. In applications such as LED lighting, power electronics, and automo- tive engine control units (ECUs), where localized and operational heat excursions can significantly reduce component life, flex circuits contribute to improved thermal regulation and longevity. Flex circuits can also be designed to be moisture- resistant, radiation-tolerant, or chemically inert, making them suitable for use or even excel in harsh or extreme environments. Improved Manufacturing and Assembly From a production perspective, flexible circuits can simplify and enhance the manufacturing pro- cess. By combining the functions of multiple rigid PCBs and their interconnects into a single flexible substrate, manufacturers can reduce material use, assembly steps, eliminate connectors, and mini- mize wiring errors while providing a pathway to faster assembly times, lower labor costs, and fewer quality control issues. In addition, flex circuits are amenable to cost-effective roll-to-roll processing and even assembly where and when suitable. One case of note has been in the manufacture of flexi- ble RFID tags. One of the transformative benefits of flexible cir- cuits is their ability to be shaped and molded into complex or irregular configurations. This enables electronics to be integrated into places that were previously inaccessible or impractical using rigid boards. Engineers can design systems that con- form to curved surfaces, wrap around structures, or, in recent years, actually integrate into and embed within textiles and biological environments (Figure 5). This new measure of design freedom supports a variety of performance improvements. In wear- able electronics, flexible circuits allow sensors and actuators to be placed precisely where they are needed—on skin, within clothing, or embedded in prosthetics—without causing discomfort or com- promising mobility. In automotive interiors, flexi- ble circuits enable seamless integration of lighting, touch sensors, and controls into dashboard con- tours and steering wheels. Additionally, flexible circuits can integrate multi- ple functionalities onto a single substrate. Anten- nas, sensors, batteries, and even passive com- Figure 5: Roll-to-roll assembly of flexible RFID tags is key to managing their cost and thus their present ubiquity. (Source: Delta ModTech)