Flexible Circuit & Heater

Design Guide

Download from
www.allflexoinur website:
c.com

h ec k o u t th e o n lin e design course: m

C flexiblecircuits.co
www.designing
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ISO 9001: 2008 • AS9100C • MIL-P-50884E • ITAR Registered • RoHS Compliant • UL Recognized • IPC Member
 TABLE OF CONTENTS

BENEFITS OF FLEXIBLE CIRCUITRY.........................................................................................................................2

Benefits, Advantages, and Features
ALL FLEX’S STANDARD CAPABILITIES................................................................................................................ 3 - 4
Design Considerations and Manufacturing Capabilities
Standard Materials
SINGLE-SIDED AND DOUBLE-SIDED CIRCUIT CONSTRUCTION...................................................................................5
Cross Sectional View, Features
When to Use Single-Sided and Double-Sided Flex
MULTI-LAYER AND RIGID FLEX CIRCUIT CONSTRUCTION..........................................................................................6
When to Use Multi-Layer and Rigid-Flex
MAXI-FLEX®.........................................................................................................................................................7
Features of these exceptionally long circuits 40'+
FLEXIBLE HEATER CIRCUITS..............................................................................................................................8-11
Flexible Heater and Hybrid Heaters
Added Value Capabilities.............................................................................................................................12
Automated Pick and Place, Circuit Testing and Potted Circuits
SURFACE DIELECTRICS OPTIONS..........................................................................................................................13
Coverlays
Liquid Photoimageable Soldermask
DESIGN GUIDELINES......................................................................................................................................14-15
Conductor Pad Design- Fillets, Tie-Downs, and Annular Rings
Shaved and Elongated Pads, Radiused Traces, and I-Beam
SHIELDING...................................................................................................................................................16-17
Solid Copper, Cross Hatched Copper
Conductive Silver
Conductive Shielding Film
Stripline Impedance Chart
RIGIDIZERS/STIFFENERS.....................................................................................................................................18
FR4, Polyimide, and Polyester
TERMINATION METHODS....................................................................................................................................19
ZIF End and Surface Mount
All Flex Fingers
ADDITIONAL TECHNICAL INFORMATION..........................................................................................................20-22
Typical Properties of Dielectric Materials
Current Carrying Capabilities and Current Rating Nomograph
IPC Specification List
COMPUTER AIDED DESIGN (CAD) INFORMATION...................................................................................................23
Design/Data Transfer Information
GLOSSARY....................................................................................................................................................24-25
REQUEST FOR QUOTE WORKSHEET.......................................................................................................................26

Revised August 2013

1 ALL FLEX • 1-877-663-7162 • www.allflexinc.com

 BENEFITS OF FLEXIBLE CIRCUITRY

1. A SOLUTION TO A 3. Replacement for 6. Thermal management/

PACKAGING PROBLEM. a circuit board high temperature
• Flexible circuits allow unique designs and wires. applications.
which solve interconnection problems. • Flexible circuits simplify system design. • Flex circuits dissipate heat at a better
• The ability to fold and form flex circuits rate than any other dielectric materials.
• Flex reduces the number of levels
enables a package size reduction. of interconnection required in an
electronic package. 7. Aesthetics.
• Flex circuits make installation and repair
• Flex circuits improve the internal
practical and cost effective. • Flexible circuits eliminate human
appearance of an electronic package,
error common in wire assemblies as
2. Reduce assembly which can have an influence on the
routing is determined by artwork and
costs. decision making process of prospective
repeatability is guaranteed.
users of the product.
• Flex circuits can be tested prior to
assembly of components. 4. Reduce weight
and space.
• Reduction of connectors and solder
joints lowers costs, and improves • Considerable weight reduction is a
product reliability. benefit over wire harnesses, and
rigid assemblies.
• Thickness can be as thin as .004 inches
(.10mm) in total.

5. Dynamic Flexing.
• The thinness of the material makes
flexible circuitry the best candidate
for dynamic flexing applications up to
millions of flexures.

ALL FLEX • 1-877-663-7162 • www.allflexinc.com 2

 DESIGN CONSIDERATIONS

FOR STANDARD MANUFACTURING

CAPABILITIES
(inquire within about nonstandard sizes)

CIRCUIT CONSTRUCTIONS: HOLE SIZE: LASER CUT:

Outline dimensions
SINGLE-SIDED NON-PLATED (Standard Processing)
+/- .003" (.25mm)
DOUBLE-SIDED THRU HOLES:
.005" (.125mm) min. drilled hole size. Edge insulation
MULTI-LAYER Tolerance +/- .0015" (.038mm) .004" (.102mm)
RIGID FLEX PLATED THRU HOLE: DRILL POSITION:
.005" (.125mm) min. drilled hole size.
SHIELDING: Tolerance +.003" (.076mm),
Tolerance of +/- .003" (.076mm)
COPPER -.005" (.125mm) ZIF END TOLERANCE:
TATSUTA, SILVER (Smaller holes can be manufactured, contact +/- .002" (.0508mm) with CpK>2.0
All Flex Sales)
STANDARD CIRCUIT SIZES: ADDED VALUE CAPABILITIES
(Longer available, considered MAXI-Flex®,
see page 7)
LINE WIDTH AND SPACING: • AUTOMATED MIXED FORM
.004" (.1mm) MINIMUM LINE FACTOR ASSEMBLY
SINGLE-SIDED: (see page 5)
up to 22" by 28" .004" (.1mm) MINIMUM SPACING • SURFACE MOUNT COMPONENTS
(558.8mm by 711.2mm) Down to 0201
(Finer lines can be manufactured, contact
DOUBLE-SIDED: (see page 5) All Flex Sales.) Thru hole assembly
up to 16" by 22" (see more on page 12)
(406.4mm by 588.8mm) CIRCUIT/BLANKING
• PLACEMENT ACCURACY TO .001"
CONSIDERATIONS:
MAXI-FLEX®: (see page 7) • RoHS COMPLIANT ASSEMBLY
up to 20" by 40' plus SOFT TOOLING:
(508mm by Length) Outline dimensions • PRECISION STENCILING
+/- .005" (.125mm)
MULTI-LAYER: (see page 6) • HEAT SINKS
Radius of inside corners minimum of
12" by 24" .023" (.584mm) • ELECTRICAL TESTING
(304.8mm by 609.6mm)
Edge insulation • FOLDING FORMING
RIGID FLEX: (see page 6) .010" min (.254mm)
6-8 Layers standard construction HARD TOOLING:
(depending on complexity and design) Outline dimensions
+/- .001" (.0254mm)
Edge insulation
.006" min (.152mm)

assist You
All Flex Circuit Design and Engineering
support will

3 ALL FLEX • 1-877-663-7162 • www.allflexinc.com

 STANDARD MATERIALS

BASE MATERIALS: SOLDER MASK: RIGIDIZERS/STIFFENERS:

Polyimide: Polyimide coverlay: FR4-drilled, routed, or scored
.0005" to .005" .0005" to .005"
Aluminum
(.012mm - .127mm) (.012mm - .127mm)
Polyimide
Polyester: Polyester coverlay:
.002" to .010" .0015" to .003" Polyester
(.050mm - .254mm) (.038mm - .076mm)
Stainless Steel
Adhesiveless Materials: Photo-imageable covercoat:
Copper thickness LPI - Liquid Photo Imagable - for high CERTIFICATIONS:
.5 oz. to 4 oz. density applications. ISO 9001: 2008 Certified
Flame Retardant: AS9100C
Laminates and Coverlay SURFACE FINISH:
MIL-P-50884E Qualified
Hot Air Solder Level (HASL)
Other Materials Upon Request RoHS Compliant
RoHS Compliant and Tin Lead
BASE COPPER: Tin Plating (RoHS Compliant) IPC Member: Product is manufactured
.5 oz. - .0007" (.018mm) thick copper Electroless and electrolytic in accordance with the requirements of
IPC-6013B Classes 1, 2, 3
1 oz. - .0014" (.036mm) thick copper Silver (RoHS Compliant)
ITAR Registered
2 oz. - .0028" (.071mm) thick copper Immersion
JCP Certified
3 oz. - .0042" (.107mm) thick copper Hard Gold over Nickel
(RoHS Compliant) UL Recognized: for single and double
4 oz. - .0056" (.142mm) thick copper sided constructions with individual
(Typically used for contacts)
5 oz. - .0070" (.178mm) thick copper polyimide layers up to 5 mil, including
Soft Gold over Nickel several surface finishes. (File # E161240)
6 oz. - .0084" (.213mm) thick copper (RoHS Compliant)
7 oz. - .0098" (.249mm) thick copper (Electrolytic - sometimes used for
bonding gold wire to the gold layer)
Thicker coppers are available (call for
information). See current carrying chart ENIG (Electroless Nickel
on page 22. Immersion Gold) (RoHS
Compliant)
(Electroless - sometimes used for
bonding aluminum wire to the nickel
under the gold)
Organic Coating
OSP (RoHS Compliant)

ALL FLEX • 1-877-663-7162 • www.allflexinc.com 4

 SINGLE-SIDED & DOUBLE-SIDED
CIRCUIT CONSTRUCTION

Single-Sided Flexible Circuits

Single-sided flexible SINGLE-SIDED FEATURES: WHEN TO USE
circuits consist of a single • Very thin construction SINGLE-SIDED FLEX:
conductive layer on a .004"-.008" (.10mm - .20mm) • Dynamic flexing applications
flexible dielectric film • 1 Conductive layer. • Unusual folding and forming applications.
(see diagram below). • Reverse bared or back bared pads, provide • Installation/service applications/repair.
access from both sides of the part. • Limitations on space / thickness
• Supported and unsupported finger areas. • Installation / Service flexing

(refer to standard materials page for material availability)

A Unique Type Of Single Sided Circuit

Sculptured Flex Circuits
1.27mm Ref
Sculptured flex circuits have variable Typical Finger

copper thicknesses within the part.

Thin copper is used for the flexible regions, 0.635mm ± 0.127mm

and thicker copper is used at the

interconnection point. Sculptured flex
0.1mm ± 0.025mm
circuits provide bare metal connections CONDUCTOR
PITCH ± 0.127mm
FINGER LENGTH
and are a highly reliable alternative to 3.175mm ± 0.635mm
0.140mm to 0.250mm ± 10%

mechanically crimped contact pins. FLEXIBLE REGION INTERCONNECTION POINT

Double-Sided Flexible Circuits

Double-sided flexible DOUBLE-SIDED FEATURES: WHEN TO USE
circuits consist of two • Component assembly available on both sides. DOUBLE-SIDED FLEX:
conductive layers • Two conductive layers. • Required when circuit density and layout can
normally connected with not be routed on a single layer.
a plated through-hole • Ground and power plane applications.
(see diagram below). • Used for shielding applications.
• Dense surface mount assembly.

(refer to standard materials page for material availability)

5 ALL FLEX • 1-877-663-7162 • www.allflexinc.com

 MULTI-LAYER & RIGID-FLEX
CIRCUIT CONSTRUCTION

Multi-Layer Construction Circuits WHEN TO USE • Ground and power • Increased circuit
MULTI-LAYER plane applications. density.
• Controlled impedance and shielding possible.
FLEX: • Used for shielding • EMI/RFI shielding.
applications. • Controlled impedance
• Required when circuit
COPPER density and layout can • Dense surface mount with shielding.
not be routed on a assembly.
PI (Polyimide) single or double layer.
ADHESIVE ADDED
BETWEEN EACH

(refer to standard materials page for material availability)

RIGID-FLEX CIRCUITS RIGID RIGID

FLEX
SECTION SECTION SECTION
Rigid-Flex circuits are characterized by 0.0014" (1 OZ./SQ. FT) COPPER

having conductors on both the flexible 0.005" FR-4

and rigid layers of the circuit. Plated thru
0.0028" (2 OZ./SQ. FT) COPPER
holes extend between the flexible and
rigid sections and electrically connect 0.005" NO FLOW PREPREG

multiple conductor layers. Rigid-flex TOP COVER LAYER

0.001" POLYIMIDE FILM
circuits are often used when components 0.001" ACRYLIC ADHESIVE

are mounted on both sides of the rigid

section. This circuit construction is known
0.001" ACRYLIC ADHESIVE
as a Type 4 circuit as defined by IPC 6013 BOTTOM COVER LAYER
0.001" POLYIMIDE FILM

and should be distinguished from a 0.005" NO FLOW PREPREG

flexible circuit with a rigid
stiffener attached. 0.0028" (2 OZ./SQ. FT) COPPER

0.005" FR-4

0.0014" (1 OZ./SQ. FT) COPPER

Inquire Within

ALL FLEX • 1-877-663-7162 • www.allflexinc.com 6

 MAXI-FLEX®

54"L Maxi-Flex® Circuit

All Flex is one of the few companies in the

world that manufactures flexible circuits in
extended lengths over 24".

All Flex has trademarked our MAXI-FLEX®

special flex circuit offering that Custom Designed Copper Flexible Circuits in • Custom termination design
allows an application to be exceptionally long lengths up to 40'+. for use with:
produced at larger than normal • Sizes from 2' to 40'+ by 20" max High density circular connectors
sizes. Maxi-flex® is a circuit that • Single-sided, double-sided, multi-layer D subminiature connectors
is typically found on one or two • Plated through holes Surface mount connectors &
conductive layers longer than 24" • Ideal for large systems and
components
in length. Additional layers may unmanned systems Pin and socket connectors
be added. • Permits tight bends Leaded components
• Eliminates bulky cabling Edge card and zif connectors
• For use in military and Crimp-on/displacement pins
aerospace applications and connectors
• Standard conductor pitch down to MAXI-FLEX® circuits can be designed for
0.030" (0.76mm) (finer pitch available, specific applications with signal, power
call ALL FLEX sales for more information) and shielding layers in one complete
interconnect package.
• Shielding possible to provide
EMI/RFI protection (IMPORTANT: DUE TO MATERIAL
AVAILABILITY in these lengths,
• Controlled impedance design available
contact All Flex staff for further
• Light Weight, dense packaging solutions information on standard
• Replacement for wire harnesses MAXI-FLEX® construction options.)

7 ALL FLEX • 1-877-663-7162 • www.allflexinc.com

 CUSTOM HEATERS
FEATURES/ADDED VALUE

All Flex has the unique capability to manufacture heaters and assemble components
All Flex can design, fabricate, and reverse engineer flexible heaters to meet customer’s exact requirements. Flexible

F L E X I B L E H E AT E R S
polyimide and silicone rubber heaters and heater component assemblies are fabricated with a variety of resistive metal
alloys to deliver custom solutions for heating capacity, watt density, and other application specific customer needs.
Typical lead times 2 – 3 weeks.

Flexible Heater Other considerations/ • PSA – Pressure Sensitive Adhesive can

Features: ADD ONS: be applied to either surface for a peel
and stick application
• Temperatures up to: • Thermistor assembly
200°C Polyimide • Heat spreaders of aluminum can be
• Heater can be built with multiple
applied to the heater to reduce the
232°C Silicone Rubber heating zones
incidence of hot spots
• Circuit size up to 22" x 30" • Quick turn available
• Designs can be manufactured to reduce
(558mm x 762mm) • Any volume quantities or eliminate heat in certain positions of
• Resistant to most chemicals • Assembly expertise the heater
• Engineered to meet specified output • Epoxy coated solder joints provide • Heaters can be designed/manufactured
strain relief and insulation and into virtually any size or shape, with or
• Flexible Heaters can be supplied as thin
environmental protection without clearance holes
as .004"
• UL Recognized • All heaters are custom designed
• Component and connector assembly
and manufactured to customer
• Soldered wire assembly for connections (File #E338387) specifications
• Epoxy reinforced soldered wires (Category KSOT2) • Special marking of part number
• Bifilar Heater - A heater that consists of or image
two parallel traces of differing resistance.
User can heat one, the other , or both
traces essentially making three heaters in
one. Bifilar heaters can be advantageous
if the user wants to keep control logic to
a minimum.

Reverse Engineer
All Flex support can Heaters can be designed and manufactured into virtually any
size and shape. Parts can be supplied with pressure sensitive
adhesive for easy attachment to heat sinks.
to meet exact requirements

ALL FLEX • 1-877-663-7162 • www.allflexinc.com 8

 CUSTOM HEATERS
POLYIMIDE & SILICONE RUBBER
Hybrid

All Flex engineering will work closely with you to ensure the proper design and layout. The following are typical
F L E X I B L E H E AT E R S

characteristics and parameters of our heater circuit products.

Design Parameters
CHARACTERISTICS TYPICAL PARAMETERS - POLYIMIDE TYPICAL PARAMETERS - SILICONE
* Note - these are standard parameters inquire within for requirements beyond this range
Size Range* Less than ½" square up to 10"x22" Less than ½" square up to 24"x30"
Temperature Range Up to 392° F (200° C) Up to 450° F (232° C)
Resistance Range Up to 250 Ω per sq in Up to 250 Ω per sq in
Metal Thickness Range* .0005" - .002" .0005" - .002"
Total Thickness Range* .0045" - .01" .03" - .06"
Dielectric Range/ Insulation Resistance 4000-5000 V/mil 400-600 V/mil
Example Power Densities 2.5 W/in²-low end, 5 W/in²-all purpose, 2.5 W/in²-low end, 5 W/in²-all purpose,
10 W/in²-rapid warmup 10 W/in²-rapid warmup
Resistance Tolerance* +/- 10% +/- 10%
Maximum Voltage Up to 115 V Up to 220 V
Standard Coverlay Thickness .001", .002", .003" and .005" .015"
Leads (if required) Length/AWG/Coating Length/AWG/Coating

Multi-zone heaters give customers full flexibility in managing their

processes while offering uniform and easy to install elements.
Available in both polyimide and silicone rubber.

HYBRID HEATERS
Now your single or double sided circuit assembly can have built-in heaters.
All Flex can take your electronic circuitry requirements and your heat requirements Advantages of a
and create a hybrid product. Typically the heater function is on one side of the Hybrid heater
base film and the electronics function is on the opposite side. By combining • Thinner overall profile
a copper layer for the electronics with a layer of resistive metal for the heater, • Reduces overall assembly weight
a hybrid circuit can be designed. Top to bottom electrical connection can be • More robust functionality
done with plated thru holes. All Flex has unique process and materials that can • Lower over all costs
accommodate even the most challenging hybrid requirements.

9 ALL FLEX • 1-877-663-7162 • www.allflexinc.com

 HEATER APPLICATIONS

MEDICAL AERONAUTICS/AEROSPACE MILITARY/DEFENSE

All Flex heaters provide precise heating All Flex is AS9100, ISO 9001:2008 Certified, All Flex is AS9100, ISO 9001:2008 Certified,

F L E X I B L E H E AT E R S
and thermal control in applications ITAR Registered, Mil-P-50884E Compliant. ITAR Registered, Mil-P-50884E Compliant.
where thermal management is
Heating technology is used extensively in All Flex Heaters provide an excellent solution
extremely important.
the Aeronautics and Aerospace industry due for high performance, densely packed
All Flex Understands: to the temperature extremes and the need electronics where space is a premium yet
for reduced weight and compact electronics. heating of components are needed.
• Medical quality requirements
All Flex heaters help to maintain high Numerous All Flex Flexible Circuits are used
• FDA traceability expectations reliability of electrical components by by prime contractors, NASA, developmental
• Medical device limiting exposure to high degrees of thermal laboratories, and government agencies.
qualification procedures contraction/expansion cycles.
Some Applications:
• Clean room/precision assembly All Flex Heaters also keep non-electrical
• Aircraft equipment
needs of medical customers components at constant temperatures for
both functional and convenience purposes. • Night vision
• Medical device product
The typical application for heaters in this • Sighting systems
development cycles
industry is not to heat devices to high • Ruggedized computers
• Small and medium volume temperatures, but to keep devices from
delivery needs getting cold. Our technology enables us to
Some Applications: fabricate heaters that remain flexible and
compliant at -55 degrees C (-67 degrees F)
• Incubator while heating to slightly above freezing.
• Operating room equipment Some Applications:
• Surgical tools • Helicopter controls
• Defibrillator • Aircraft controls
• Dialysis equipment • De-icing systems
• Blood analysis equipment • Satellite hardware
• Medical instrumentation and
• Cockpit systems Lab Analysis Heater
laboratory equipment

Breath Analyzer

ALL FLEX • 1-877-663-7162 • www.allflexinc.com 10

 HEATER APPLICATIONS &
STOCK HEATERS
F L E X I B L E H E AT E R S

Outdoor Electronics STOCK HEATERS:

(for production products or test/evaluation)
Devices and equipment that are exposed to
cold temperatures creates design challenges Generally our customers have unique design
for manufacturers. Typical thermal cycling requirements that necessitate customization
introduces molecular expansion issues that for their particular device or application,
can impact electronics, cause mechanical however one of our standard heaters may
wear, introduce moisture variation, restrict meet your needs, All Flex offers standard,
moving parts, and other functional and non-custom flexible heaters. These heaters
operational problems. are classified as either Stocked or Build to
Order (BTO) and are available without a
Some Applications:
tooling or set-up charge.
• Automated Teller Machines
Select size/shape, resistance, or watt
• Outdoor LED and density (watts per square inch) to determine
Canister Lighting if a particular stock product meets your
• Outdoor LCD Screen needs then assess the additional options
below that may be required.
• Ruggedized electronic and computer
devices made to operate in extreme Stocked heaters options:
weather conditions • Each stocked heater is available with a
pressure sensitive back-piece cut to All Flex heaters can be supplied with
General & Industrial the same size as the heater. PSA (Pressure Sensitive Adhesive) on
Electronics the back of the heater with a release
• Aluminum heat-dissipation shield, cut
All Flex Heaters are used in a wide variety of liner for easy peel and stick, the PSA
to the same size as the heater.
electronic applications to assist in the makes installation quick and easy.
performance of our customers’ end products. • Custom marking is available as
specified and desired by the customer. To order call:
Some Applications:
• The addition of wires and associated 877-663-7162
• Food service equipment
wire characteristics or email:
• Storage tanks customersupport@allflexinc.com
• UL Recognition
• Battery heaters to enhance
Visit: WWW.ALLFLEXHEATERS.COM for
battery performance
a complete listing of all standard stock
• Photo processing heaters, technical detail, lead times,
• Outdoor antenna pricing, option pricing, etc.

• Hand-held scanners

Our Vision...
is to be your

for flex...

11 ALL FLEX • 1-877-663-7162 • www.allflexinc.com

 ALL FLEX ADDS VALUE

All Flex has the capability to AUTOMATED PICK AND Other All Flex Added
quickly design, manufacture PLACE CAPABILITY Value Capabilities
and deliver in volumes from PROVIDES Complex • Thru hole assembly
prototype to production. All Flex Assembly Combinations • Flexible circuit folding and forming
Including: (see page 15)
has manufactured hundreds of • Electrical testing
• Surface mount components down
designs for the military, medical to 0201 • Heat Sinks
and industrial markets. • Precise vision system allows placement • Nomenclature Screening
accuracy to .001" • Stiffener placement
• Fine pitch capability to .5mm pitch • Design and manufacturing
• Leaded devices support – concept to completion
• Tactile domes Circuit Testing Capability
• Staked terminals • Capability
Solderability • Microsections
• Unlimited component configurations • Ionic contamination
Solderability • Continuity
• RoHS Compliant assembly • Dimensional tolerance
Ionic contamination • Inductance
• Thermal testing
Dimensional tolerance • Capacitance
• Virtually all SMT components including
discretes, SOICs, PLCCs, QPPs, & BGA's • Dielectric net-to-net
Thermal testing • Resistance
• Auto fiducial correction • Insulation resistance (IR)
Microsections • Impedance

Potted Circuits
connector securely adhered with
potting compound to perform in rugged
applications where vibration is typical

Automated assembly
HAND ASSEMBLY • Solder Screener
Automated screening of solder onto
• Operators certified to J-STD arrays/panels using solder stencil
• Lead and lead free capability Lead and lead free capability
• ESD controls • Selective Soldering
Automated ability to solder leads on
through hole connector
Lead and lead free capability

ALL FLEX • 1-877-663-7162 • www.allflexinc.com 12

 SURFACE DIELECTRICS OPTIONS

Surface dielectrics are applied to the POLYIMIDE/POLYESTER LIQUID PHOTOIMAGEABLE

outside layers of the circuit to insulate COVERLAY SOLDERMASK
the copper conductors. Coverlay is a polymer film coated with a Liquid Photoimageable Soldermask
thermoset adhesive. These materials are (LPI) is produced by a photo
Following are types of surface normally machined and shaped with a lithography process and used to
dielectrics used at All Flex. drilling process. Drilling limits the shapes precisely locate the dielectric
available on coverlay features. Coverlay can on the flex circuit features.
be punched or blanked in lieu of the drilling This process enables unique
process and is normally done for large openings to be applied
coverlay openings. anywhere on the circuit. LPI
is usually not used with 2oz.
VIA HOLE: copper or above due to the thickness of the
Plated thru hole generally covered copper as it may not conform around the
with coverlay area of some copper features.

COMPONENT HOLE: VIA HOLE:

.010" (.254mm) minimum larger Plated thru hole generally covered
than the copper pad with soldermask

FEATURE DEFINITION: LPI Opening =.006" minimum larger than

.008" (.20mm) minimum pad with .004" minimum
web spacing

Surface Dielectrics Options

Liquid Photoimageable Soldermask (LPI)
Advantages Disadvantages
Higher pattern resolution Not recommended for
dynamic flex applications
Eliminates punching and Less robust mechanically
drilling of access holes
Polyimide/Polyester Coverlayer Films
Advantages Disadvantages
Excellent dynamic Adhesive may be
Note: Coverlay openings can be individual bared pads or group bared pads flexibility susceptible to
depending on area available. cleaning solvents
Note: Group bared pads are used when there is not enough room Pinhole free Requires pre-cutting
to have individual openings. and/or pre-punching
Highest dielectric strength Susceptible to
misregistration/
dimensional change

13 ALL FLEX • 1-877-663-7162 • www.allflexinc.com

 DESIGN GUIDELINES:

CONDUCTOR PAD DESIGN

AND FILLETING
This section of our guide addresses rules use, the following information is conductor pattern on all part numbers
specifically pertaining to conductor and recommended to produce the to incorporate these reliability and
pad design recommendations. Due to highest yielding and best functioning manufacturability enhancements.
the flexible nature of the material during flexible circuit. We call this “flexizing”
both manufacturing and application the design. All Flex will flexize the

CONDUCTOR PAD DESIGN: FILLETING:

Pads should have tie-downs (also called All pads, on both through-hole and surface
anchoring spurs or rabbit ears). Tie-downs are mount pads, should be filleted to reduce
captured by the coverlay to anchor the copper to stress points. This helps eliminate breaking
prevent separation between the copper and the during flexing.
base material during assembly.

LAND PATTERN DESIGN

(see IPC-7351)

CALCULATING PAD SIZE:

Recommended pad size is dependent on the
component pad requirement that is specific to
your application.

FORMULA:
HOLE SIZE (FINISHED) + CUSTOMER REQUIRED TOLERANCES + ALL FLEX TOLERANCE = pad size required
.030" (.76mm) ±.003" (.07mm) .020" (.50mm) .053" (1.34mm)

ALL FLEX • 1-877-663-7162 • www.allflexinc.com 14

 DESIGN GUIDELINES:

TO INCORPORATE IN BENDING
AND FOLDING DESIGNS

Radiused Traces help Fold lines may be designated by Bend RaDius of a flex should
to alleviate breaking during folding “tick” marks which may be either in the be approximately 10 times the material
and bending. copper layers or silkscreen layers. These thickness and at least .050" away from the
features aid in bending and designating plated through hole.
I-Beam constructions occur when the bend locations.
conductors on both layers lie directly on r=10 x T
top of each other, increasing the stiffness
of the circuit through fold areas. A better
alternative is to stagger conductors,
alternating their location to retain the
maximum flexibility of the circuit.

Circuit trace width should

not change in bend areas and the transition
should be at least .030" (.76mm) from the
fold line. Button Plating/Pads
Only Plating is a process that
allows for the plated through holes to
maintain their connection while the traces
are not plated, allowing the circuit to have
increased flexibility.

15 ALL FLEX • 1-877-663-7162 • www.allflexinc.com

 SHIELDING

If your application requires limits in

electromagnetic and/or electrostatic
interference, shielding may be required.
Shields are material around a conductor
or group of conductors that limit
these factors.

SOLID COPPER: CONDUCTIVE SILVER: CONDUCTIVE SHIELDING FILM:

Solid Copper is the most common method of Conductive silver can be substituted for Metalized film with a conductive adhesive
shielding. Solid copper shields increase the the copper for shielding purposes in coating is thermally bonded to flexible circuitry.
rigidity of the circuit, and should be included in some applications. Silver shielding is not Selective openings in the coverlay film allow the
thickness to bend radius ratios. Copper shield recommended for a dynamic flexing application conductive adhesive to electrically contact the
can be put on one or both sides of the circuit. due to its brittle characteristic, and may be flex circuit. This creates a shielding layer by the
Solid copper can also cover selective conductors. prone to cracking in severe bending applications. contact between the metalized film and the
Silver can be a solid or crosshatched shield and ground traces.
CROSSHATCHED COPPER: can be put on one or both sides of the circuit.
Crosshatching is an artwork design that relieves It can also cover selected conductors only.
much of the copper shield areas by the use of
a pattern. Crosshatching helps the circuit to
retain its flexibility and can be put on one or
both sides. Crosshatch shielding can also cover
selective conductors.

Note: Additional shielding options exist,

such as shielding between circuit conductor.
Contact All Flex Staff for further details.

ALL FLEX • 1-877-663-7162 • www.allflexinc.com 16

 SHIELDING

CHARACTERISTIC IMPEDANCE:
Controlled impedance is important in high speed digital circuitry to avoid signal reflectance and
power loss. The impedence of a flexible printed circuit depends on dielectric constant of the
base material, conductor width, conductor thickness and dielectric thickness.

STRIPLINE SINGLE ENDED MICROSTRIP

POLYMIDE COVERLAY
ADHESIVE
COPPER SIGNAL
ADHESIVE

POLYMIDE
T=Copper Thickness
H=Ground Plane Spacing ADHESIVE
W=Conductor Width
COPPER REFERENCE PLANE

POLYMIDE COVERLAY

Flexible Polyimide Circuit – Impedance Reference Chart

SINGLE ENDED MICROSTRIP
Trace Width for Trace Width for Trace Width for Trace Width for
Material Thickness 50 ohms Impedance 50 ohms Impedance 75 ohms Impedance 75 ohms Impedance
Including Adhesive 1/2 oz copper 1 oz copper 1/2 oz copper 1 oz copper
0.002 0.0036 0.0032 0.0015 >.001
0.003 0.0057 0.0053 0.0025 0.0013
0.004 0.0078 0.0074 0.0035 0.0028
0.005 0.0102 0.0096 0.0050 0.0041
0.006 0.0122 0.0117 0.0060 0.0050
0.007 0.0144 0.0139 0.0070 0.0060
0.008 0.0166 0.0161 0.0080 0.0068
0.009 0.0189 0.0184 0.0088 0.0085
0.010 0.0211 0.0206 0.0105 0.0095
All calculations assume .002 thick coverlayer, 3.4 dielectric constant and 50% trace/ 50% space on differential pairs

17 ALL FLEX • 1-877-663-7162 • www.allflexinc.com

 RIGIDIZERS/STIFFENERS

Often circuit applications require FR4/G10 STIFFENERS: POLYIMIDE OR POLYESTER

support in areas where connectors or • Come in a variety of thicknesses such STIFFENERS:
other components are applied. Here as .010" (.25mm), .020" (.50mm), • Come in a variety of thicknesses
are the recommended types of .031" (.78mm), .047" (1.19mm) and from .001" (.02mm) up to
guidelines for stiffeners. .062" (1.57mm). .015" (.38mm) or higher.
• Can be bonded to a flex circuit using • Can be bonded to a flex circuit using a
a pressure sensitive adhesive or a pressure sensitive adhesive or a thermal
thermoset adhesive. set adhesive.
• Are normally used to give added rigidity • Can be used to give added thickness
under a component area. under conductors to meet ZIF
• Used as a carrier panel for automated connector requirements. .
assembly processing. • Can be used to give added strength in
• Hole size in the stiffener should high wear areas.
be .015" (.38mm) larger than • Can be blanked at the same time as the
the circuit thru-hole to allow for circuit outline to meet tight tolerance
registration tolerances. requirements.

LOCATION OF STIFFENER:
Stiffener and coverlay termination
points should overlap a minimum of
.030" (.76mm) to avoid stress points.
Eliminating stress points reduce the
(This is the PREFERRED METHOD because there is not common ending
chance of traces breaking. point of the coverlay and stiffener.)

(This form is NOT RECOMMENDED because it allows potential stress and

cracking points where the coverlay and stiffener end at a common edge.)

ALL FLEX • 1-877-663-7162 • www.allflexinc.com 18

 TERMINATION METHODS

There are many ways to terminate CRIMPED CONTACTS ADDITIONAL CUSTOM

a flexible circuit. Following are AND DISPLACEMENT TERMINATION OPTIONS:
common methods for consideration. CONNECTORS: • High density circular connectors
• Contacts crimp through the dielectric • D subminiature connectors
ZIF CONNECTORS: material into the copper conductor.
Zero Insertion Force connectors are a popular • Pin and socket connectors
method to terminate a flexible circuit. ZIF • Contacts are available for .100" (2.54mm)
or .050" (1.27mm) centers. • Leaded components
connector fingers on the flex circuit insert
into a mating connector. The ZIF end inserted • Centerline housings are also available to RECOMMENDED SUPPLIERS
into the connector are usually located on a encapsulate the contact.
rigid board.
LIST FOR FLEXIBLE CIRCUIT
SCULPTURED (UNSUPPORTED) CONNECTORS:
Blank tolerance +/-.002"
TRACES AND POWER FLEX: 1. Digi-Key (800) 344-4539
www.digikey.com
• Thicker copper allows flexible circuit
2. NAC Semi (866) 651-2901
designs to carry higher current through
www. nacsemi.com
small spaces.
3. Samtec (800) 726-8329
• Selective etching allows a reduction in www.Samtec.com
copper thickness in selective areas for
4. TTI (800) 225-5884
THRU-HOLE OR SURFACE increased flexibility.
www.TTIInc.com
MOUNT CONNECTORS: • Copper thickness from 0.003" (0.076mm)
These are the traditionally used connectors in to 0.010" (0.254mm)
today’s circuit boards.

Interconnection Point

Flexible Region/Thinner Copper

Request
Sculptured (unsupported) Traces

quotes, samples,
and design consults online
www.allflexinc.com

19 ALL FLEX • 1-877-663-7162 • www.allflexinc.com

 ADDITIONAL TECHNICAL
INFORMATION

IPC INFORMATION Materials Circuits and Assembly

The following list contains the IPC-4202 (Quality Guidelines)
Flexible Base Dielectrics IPC-A-600
IPC specifications that you can
IPC-4203 Acceptability of Printed Boards
reference in regards to specific Adhesive Coated Dielectric Films IPC-A-610
materials, design, performance and IPC-4204 Acceptability of Printed
assembly questions. Flexible Metal-Clad Dielectrics Board Assemblies
IPC-4101 IPC/EIA J-STD001
Rigid PC Board Materials Requirements for Soldered Electrical &
Electronic Assemblies
Design Visit the IPC web site @ www.ipc.org
IPC-FC-2221
Generic Standard on Printed Circuit Check out the online design course:
board Design www.designingflexiblecircuits.com,
IPC-FC-2222 it’s self paced and free. The course
Rigid Circuit Boards material is divided into several
IPC-FC-2223 chapters of solid technical
Flexible Circuits information about flexible circuit
materials, constructions and design
Performance layout conventions. It allows
designers, or engineers an
IPC-6011
Generic Performance Specifications for opportunity to self-educate about
Printed Circuits flexible circuits.
IPC-6012
Qualification and Performance for
Rigid Circuit Boards
IPC-6013
Qualification and Performance for
Flexible Circuits

ALL FLEX is an active, award winning

IPC Member, holding chair positions on the
flexible circuit materials committee.

ALL FLEX • 1-877-663-7162 • www.allflexinc.com 20

 ADDITIONAL TECHNICAL
INFORMATION

TYPICAL PROPERTIES OF DIELECTRIC MATERIAL FOR FLEXIBLE PRINTED CIRCUITRY

POLYIMIDE
PROPERTY (TYPICAL) UNITS POLYIMIDE (Adhesiveless) POLYESTER
REPRESENTATIVE TRADE NAME KAPTON KAPTON MYLAR
PHYSICAL
Thickness Range mil 0.5 to 5 1-6 2-5
Tensile Strength (@25° C) psi 25,000 50,000 20,000 to 35,000
Break Elongation % 70 50 60 to 165
Tensile Modulus (@25° C) 100,000 psi 4.3 .7 5
Tear Initiation Strength lb/in 1000 700-1200 1000 to 1500
Tear Propagation Strength g/mil 8 20 12 to 25
CHEMICAL
Resistance to:
Strong Acids Good Good Good
Strong Alkalis Poor Good Poor
Grease and Oil Good Good Good
Organic Solvents Good Good Good
Water Good Good Good
Sunlight Good Good Fair
Fungus Non-nutrient Non-nutrient Non-nutrient
Water Absorption (ASTM D570) % (24 hours) 2.9 .8 <0.8
THERMAL
Service Temperature (min/max) degree C -125/+200 -125/+200 -60/+105
Coefficient of Thermal Expansion (@22° C) PPM/degree C 20 20 27
Change in Linear Dimensions
(100° C, 30 min) % <0.3 0.04-0.02 <0.5
ELECTRICAL
DIELECTRIC CONSTANT (ASTM D150) 1MHz 3.4 3.4 3
DISSIPATION FACTOR (ASTM D150) 1MHz 0.01 .003 0.018
DIELECTRIC STRENGTH (ASTM D149)
@ 1 mil thickness V/mil 6000 6000 3400
Volume Resistivity (ASTM D257) ohm-cm 1.0E+16 1.0E+16 1.0E+16

21 ALL FLEX • 1-877-663-7162 • www.allflexinc.com

 CURRENT CARRYING CAPABILITIES FOR EXTERNAL TRACES IN AIR
COPPER WEIGHT
AMPS 1/2 OZ. 1 OZ. 2 OZ. 3 OZ. 4 OZ. 5 OZ. 6 OZ. 8 OZ.
(.0007") (.0014") (.0028") (.0042") (.0056") (.007") (.0084”) (.0112)
CONDUCTOR WIDTH IN INCHES
0.5 .013" .008" N/A N/A N/A N/A N/A N/A
1.0 .028" .017" .013" N/A N/A N/A N/A N/A
1.5 .040" .027" .020" N/A .012" .005" .003” N/A
2.0 .053" .040" .030" .0235" .020" .018" .016” .013”
2.5 .080" .060" .042" .0325" .0285" .024" .023” .018”
3.0 .100" .083" .057" .045" .0387" .035" .030” .024”
4.0 .160" .120" .088" .066" .055" .048" .043” .037”
5.0 .225" .158" .118" .09" .074" .065" .059” .048”
6.0 .285" .195" .153" .117" .094" .082" .074” .062”
(off chart)
7.0 N/A .250" .187" .145" .124" .105" .0905” .075”
(off chart)
8.0 N/A .307" .232" .180" .1485" .130" .122” .095”
(off chart)
This chart gives recommendations for width of conductor needed to carry current on different copper thicknesses.
For informational purposes only.
Additional helpful link: http://circuitcalculator.com/wordpress/2006/01/31/pcb-trace-width-calculator/

CURRENT RATING NOMOGRAPH:

EQUIVALENT AMERICAN WIRE GAUGE (A.W.G.) SIZE
20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
.250
MP
.200 4.0 A
P
AM

.150 MP
3.0 A
7.0

P
AM

MP
.100 2.5 A T
6.0

P
AM

W
FLAT CONDUCTOR WIDTH, W (INCHES)

5.0

.070 MP
2.0 A
.050 MP
CONDU
CTOR W 1.5 A
.030 IDTH/
TH ICKNE MP
SS, W/
T=5 1.0 A
.020 EQUIV
ALENT
ROUN 1/2
.015 D WIR OZ
E CUR A COP
MP
RENT
RATIN
P ER
(T= 0.5 A
.010 G 1O .00
Z CO 07”
2O PPE )
.007 Z CO R (T
B PPER =.0 AMP
(T= 014 0.25
.005 .00 ”)
28”
.003 )
10° C RISE AT 20° C AMBIENT
.002
SINGLE COPPER CONDUCTOR
.0015 WITH .010” THICK INSULATION
.001

10 15 20 30 50 70 100 150 200 300 500 700 1000 1500 2000 3000

CONDUCTOR RESISTANCE ° (OHMS/1000 FEET)
Relation between current rating and size of a single conductor for constant temperature rise in air. Conductor dimensions above the line
“WIDTH/THICKNESS = 5" are preferred for ease of manufacture.

ALL FLEX • 1-877-663-7162 • www.allflexinc.com 22

 COMPUTER AIDED DESIGN (CAD)
INFORMATION

DATA FORMATS: TO COMMUNICATE: INFORMATION CAN BE

RS 274X (Gerber) BY E-MAIL: RECEIVED IN A NUMBER
PDF General Mailbox: OF WAYS:
information@allflexinc.com • Mechanical print/sketches
dwg
Call ALL FLEX: • Schematic drawings
IGES engineering toll free at
DXF • Component Specifications
877-663-7162
• Existing Artwork to be Scanned
README FILE SHOULD: • Fax (507) 663-1070
• Contain your company name • E-mail (information@allflexinc.com)
• Contain a list of included files and
• Secure FTP: ftp://mail.allflexinc.com
their functions
(contact us for password)
• Contain your company contact and
phone number • Request a quote: rfq@allflexinc.com
DESIGN: ALL FLEX OFFERS
THE FOLLOWING DESIGN
OPTIONS FOR OUR
CUSTOMERS.
- Reverse engineering of existing
parts, design from concept, or design
from schematic.
- Gerber creation: Contact ALL FLEX sales
for more information.
- Critique of customers design for flexibility
and manufacturability.

Q UOTES in 24 hours
We provide

23 ALL FLEX • 1-877-663-7162 • www.allflexinc.com

 GLOSSARY
Annular Ring Clearance Hole Dielectric
That portion of conductive material A hole in a conductive pattern that is larger A material with a high resistance to the flow
completely surrounding a hole. than and coaxial with a hole in the base of direct current, and which is capable of
material of a printed board. being polarized by an electrical field.
Artwork
An accurately-scaled configuration that is
Conductive Foil Dry Film Resist
used to produce the ‘‘Artwork Master’’ or A sheet of metal that is used to form a A composite material where a photosensitive
‘‘Production Master.’’ conductive pattern on a base material. emulsion that is sensitive to portions of the
light spectrum and is either carried by or
Back-Bared Land Connector sandwiched between polymer release
A land in flexible printed wiring that has a A device used to provide mechanical films and is used to expose imagery on
portion of the side normally bonded to the connect/disconnect service for printed boards.
base dielectric material exposed by a electrical terminations.
clearance hole. Enig
Copper Weight
Electroless Nickel Immersion Gold used
Base Film The mass of copper per unit area for a foil, as surface treatment for soldering and
The film that is the base material for the typically expressed in ounces per square foot electrical contact.
flexible printed wiring board and on the or grams per square centimeters (these units
surface of which the conductive pattern can are not equivalent). Etching
be formed. When the heat resistance is The chemical, or chemical and electrolytic,
required, polyimide film is mostly used, and Covercoat removal of unwanted portions of conductive
polyester film is usually used when the heat Material deposited as a liquid onto the or resistive material.
resistance is not required. circuitry that subsequently becomes a
permanent dielectric coating. Exposure
Blanking The process of generating a pattern within
Cutting a sheet of material into pieces to the Coverlay
a photosensitive material through a
specified outline. The layer of insulating film and adhesive chemical reaction using either laser direct
that is applied totally or partially over a imaging or conventional imaging with a
Bondstrength conductive pattern on the outer surfaces working phototool.
of a printed board.
The force perpendicular to a board’s surface
required to separate two adjacent layers of Fiducial
the board, expressed as force per unit area. Crosshatching
A printed board feature (or features) that is
The breaking up of large conductive areas by (are) created in the same process as the
Characteristic the use of a pattern of voids in the conductive pattern and that provides a
Impedance conductive material. common measurable point for component
The resistance of a parallel conductor mounting with respect to a land pattern or
structure to the flow of alternating current Delamination land patterns.
(AC), usually applied to high speed circuits, A separation between plies within a base
and normally consisting of a constant value material, between a base material and a Flexize
over a wide range of frequencies. conductive foil, or any other planar
Modification of an artwork to optimize
separation within a printed board.
manufacturability and reliability of the
Circuitry Layer conductor trace pattern.
A layer of printed board containing
conductors, including ground and
voltage planes.

ALL FLEX • 1-877-663-7162 • www.allflexinc.com 24

 GLOSSARY

Flexible Heater Moisture PSA

Custom designed polyimide and silicone Absorption Pressure Sensitive Adhesive.
rubber heaters fabricated with a variety of The amount of water the base material
resistive alloys for custom heating solutions. will absorb. Resistive Metal
Copper alloy or other metals selected
FR4 Pads Only Plating for their resistive properties to design
Epoxy based hardboard material used to A process with copper plated only in thru flexible heaters.
make stiffeners. holes and on pads. Used to reduce thickness
and increase flexibility and with controlled Rolled Annealed
Gerber Data impedance requirements. Also referred to as Copper rolled foil to a predetermined
Most common PCB electronic data format. button plating. thickness and then treated through an
Consists of aperture selection and operation annealing process.
commands and dimensions in X- and Panel Plating
Y-coordinates. The plating of an entire surface of a panel Shielding, Electronic
including holes. A physical barrier, usually electrically
Land conductive, that reduces the interaction of
A portion of a conductive pattern usually Pattern Plating electric or magnetic fields upon devices,
used for the connection and/or attachment The selective plating of a conductive pattern circuits or portions of circuits.
of components. and associated holes.
Silkscreen
Laser Direct Imaging Photoimaged A process for applying nomenclature legend.
(LDI) Soldermask
The selective exposure of patterns onto a Produced by a photo controlled process and Stiffener Board
photosensitive material (such as dry film or used for tight pad spaces. This process A material fastened to the surface
liquid) without using a working phototool enables unique openings to be applied of a printed board to increase its
(artwork master). anywhere on the circuit. mechanical strength.

Minimum Annular Ring Photoresist Via

The minimum ring of metal(s) at the A photo-chemically reactive material, which A plated-through hole that is used as an
narrowest point between the edge of a hole polymerizes upon exposure to ultraviolet interlayer connection, but in which there is
and the outer edge of a circumscribing land. energy at a given wavelength customarily no intention to insert a component lead or
(This determination is made to the drilled used to define an etching, plating, or other reinforcing material.
hole on internal layers of multilayer printed selective stripping pattern on a substrate.
boards and to the edge of the plating
on external layers of multilayer and Polyimide
double-sided printed board). Source for most terms: “Terms and Definitions
The synthetic polymer that has more than for Interconnecting and Packaging Electronic
two imide radicals in the main chain. Circuits” IPC-T-50
DuPont trademark is Kapton®. See www.ALLFLEXINC.com/EngineeringTools/
Glossary for a complete listing of flexible
circuitry terms.

25 ALL FLEX • 1-877-663-7162 • www.allflexinc.com

 REQUEST FOR QUOTE (RFQ) GUIDELINE
You can also request online www.allflexinc.com
Flexible Circuits Part Number:___________________

Email To: information@allflexinc.com * Approximate Part Dimensions:______ Inches_______ MM

or Fax To: 507-663-1070 Number of conductive layers:_______________________
Attention: Sales Applications Engineers
Smallest Diameter hole: __________________________
Your Name:______________________________ Approximate Overall Thickness: ______________________
Email:_________________________________ * Quantity to Quote:___________________________

Phone:_________________________________ Surface Finish: HASL Tin ENIG Elec. Gold OSP

Immersion Nickel Immersion Silver Unsure
Company:_______________________________
Does the part require assembly?
Address:________________________________ Yes, but All Flex will not handle the assembly
All Flex Design Considerations Yes, include assembly pricing (please provide All Flex BOM)
No
Please provide All Flex with Heater CAD data, pdf or sketch
Undetermined
if available.

Heater Part Number:___________________________

* Approximate Part Dimensions:_____ Inches /OR______MM
* Quantity to Quote:___________________________
* Material construction: Polyimide OR Silicone Rubber
* Voltage__________________________________
* Power (Watts)______________________________
Temperature range required:________________________
Approximate overall thickness:______________________
Wires/if any: (length/gauge/insulation):_________________
Does the heater require assembly?
Yes, but All Flex will not handle
Yes, include assembly pricing (please provide All Flex BOM)
No
Undetermined
* Indicates required field.

ALL FLEX • 1-877-663-7162 • www.allflexinc.com 26

ISO 9001: 2008 Certified
AS9100C
MIL-P-50884E Qualified
RoHS Compliant
ITAR Registered
UL Recognized
IPC Member

1705 Cannon Lane

Northfield, MN 55057
1.877.663.7162
FAX 507.663.1070
E-mail information@allflexinc.com
www.allflexinc.com