Complex Turn Key PCB Assembly With Rigid Flex / HDI Capability
Complex electronics demand complex board structures. Rigid-flex designs that combine flexible circuits with rigid boards. HDI (High-Density Interconnect) designs with micro-vias and fine lines for miniaturization. Multi-layer boards with controlled impedance and blind/buried vias. These structures require specialized manufacturing expertise that standard EMS providers often lack. At Studio, we have that expertise. Our Complex Turnkey PCBA with Rigid-Flex & HDI Capability delivers advanced assemblies for the most demanding applications.
Our complex board manufacturing capabilities are supported by 12 fully automated SMT production lines, automated wave soldering, programmable robotic soldering, and comprehensive inspection equipment including AOI, SPI, 3D X-Ray, ICT, FCT, flying probe testers, and an accredited reliability laboratory. We handle rigid-flex, HDI, high-layer-count, and other complex board types with precision and reliability.
Rigid-flex boards combine the durability of rigid PCBs with the flexibility of flex circuits. This combination enables space savings, weight reduction, and dynamic flexing applications:
| Rigid-Flex Capability | Specification |
|---|---|
| Layer Count | Up to 20+ layers in rigid sections; up to 6+ layers in flex sections |
| Flex Materials | Polyimide, high-temperature polyester, ultra-thin copper |
| Stiffener Options | FR-4, polyimide, stainless steel, aluminum |
| Special Processes | Controlled impedance, impedance matched flex, dynamic flex applications |
| Coverlays | Polyimide coverlay, photoimageable coverlay, overlay applications |
| Plating | Electrolytic copper, ENIG, OSP, selective gold, hard gold |
HDI technology enables higher component density and smaller form factors:
| HDI Capability | Specification |
|---|---|
| Via Types | Blind vias, buried vias, micro-vias, stacked via-in-pad, staggered vias |
| Minimum Via Diameter | Down to 0.075mm (micro-vias) |
| Minimum Trace Width/Spacing | Down to 0.05mm |
| Layer Count | Up to 20+ layers with sequential lamination |
| Build Construction | 1+N+1, 2+N+2, 3+N+3, any-layer HDI |
| Materials | High-Tg FR-4, Rogers, PTFE, hybrid constructions |
Design Review – Our engineering team reviews your rigid-flex or HDI design for manufacturability. We check for flex-to-rigid registration, material selection, bending radius, and via placement.
Material Selection – We select appropriate materials for your application: polyimide for flex, high-Tg FR-4 for rigid sections, and appropriate adhesives and coverlays.
Fabrication – Board fabrication follows the specific requirements of rigid-flex and HDI designs. This includes controlled impedance, micro-via formation, and sequential lamination.
Assembly – Assembly on our 12 automated SMT lines with handling protocols specific to rigid-flex boards. Automated soldering processes are optimized for mixed-board constructions.
Inspection – 3D X-Ray inspection for hidden joints and vias. AOI and SPI for surface components. Electrical testing for connectivity and impedance verification.
Testing – FCT for functional verification. Environmental testing as required for your application.
| Application Area | Why Rigid-Flex or HDI |
|---|---|
| Medical Implantables | Miniaturization, reliability, biocompatibility |
| Aerospace & Defense | Weight reduction, vibration resistance, reliability |
| Wearable Electronics | Dynamic flexing, space efficiency, light weight |
| Automotive | Space constraints, vibration resistance, reliability |
| Consumer Electronics | Miniaturization, cost efficiency, form factor |
| Telecommunications | High-density, signal integrity, performance |
- Rigid-Flex Expertise – Full capability for rigid-flex and flex circuit assembly
- HDI Capability – Micro-vias, blind/buried vias, fine-line designs
- 12 Automated SMT Lines – Precision assembly for complex boards
- 3D X-Ray Inspection – Full verification of hidden joints and vias
- Controlled Impedance – Verification of impedance-controlled designs
- Comprehensive Testing – AOI, SPI, ICT, flying probe, FCT
- Engineering Support – DFM review and design optimization
- Full Traceability – Complete material genealogy for every board
Rigid-flex, HDI, and other complex board types require specialized manufacturing capability. With Studio's Complex Turnkey PCBA with Rigid-Flex & HDI Capability, you gain a partner with the technical expertise and manufacturing infrastructure to bring your most demanding designs to life. Contact us today to discuss your complex project requirements.
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