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Design Considerations for Tabs in Flexible Circuits When integrating copper or nickel tabs into a flex circuit, material selection is only one part of the de- sign equation. Engineers also need to consider: • Mechanical transition: The interface be- tween rigid metal tabs and flexible polyimide must be designed carefully to manage stress and prevent fatigue over time. • Plating and finish requirements: Depend- ing on the electrical or mechanical function, finishes such as tin, nickel, or gold may be needed. • Forming requirements: Some tabs may re- quire bending or pre-forming after fabrication. • Assembly environment: Temperature expo- sure, chemicals, sterilization requirements, and repeated-use cycles can all influence material selection. I've found that material selection becomes much easier once the application is clearly defined. FLEX007 | F L E X C O N N ECT I O N S Engineers naturally gravitate toward conductivity, strength, or cost, but the best choice usually comes from balancing all three while considering how the finished product will actually be used. That's also why I encourage designers to involve their flex circuit manufacturer early in the design process. A short conversation before the design is finalized often uncovers considerations that are difficult to identify from a drawing alone. Copper and nickel have each earned their place in flexible circuit design. Understanding where each performs best helps create products that are easier to manufacture, more reliable in the field, and less likely to require design changes later. I-CONNECT007 Zack Schaner is a senior applications engineer for Flexible Circuit Technolo- gies. To read past columns, click here. SEPTEMBER 2026 I I-CONNECT007 MAGAZINE 67 ATTRIBUTE COPPER TABS NICKEL TABS Electrical conductivity Excellent Moderate Mechanical strength Moderate High Wear resistance Moderate Excellent Corrosion resistance Good with finish Excellent Ease of integration Excellent Good Cost Lower Higher Best suited for Power and signal Mechanical contact and durability FLEX007 | F L E X C O N N ECT I O N S