Flex Circuits Be Used in Aerospace Applications

A flex circuit is simply a printed circuit board (PCB) that can bend. Often, it is used in applications where there are space constraints or mechanical stresses that could cause damage to rigid PCBs. However, there are many other applications where flex technology can provide significant benefits including:

In fact, flexible circuits have already been used in some of the world’s most innovative products, such as the smartwatch and the Apple iPad Mini. They are also a crucial component of some of the most advanced medical devices on the market, such as heart pacemakers and hearing aids.

Whether you are designing a new product or replacing components on an existing assembly, flex circuit can offer many advantages over traditional PCBs, including increased device density and lower weight. These thin, conductive substrates can be easily bent and manipulated multiple times during installation without electronic failure. Additionally, they allow for improved airflow and can fit into tight spaces where rigid boards cannot.

Can Flex Circuits Be Used in Aerospace Applications?

A flex circuit typically begins with a base film like polyester or polyimide, which is etched to include the conductor pattern. This film is then covered with a coverlay, which protects the copper from moisture and dirt. The ends of the traces are then terminated to either a connector or a stiffener, which helps to maintain shape and protect against stress. Stiffeners are especially important when flex circuits are being used in high-speed applications or with high voltage.

The conductor patterns in a flex circuit can be single-sided or multi-layer, depending on the needs of the application. Single-layer flex circuits use one or more copper foil layers that are bonded to the base film with an adhesive. Often, this process is continuous, though it can be interrupted with openings for soldering, allowing the flexibility of the circuits to be altered as needed. Multi-layer flex circuits are designed to have more complex connections that can be formed in three dimensions and can connect to multiple connectors at once. This allows for a more efficient design with reduced weight and improved performance in harsh environments.

When designing a flex circuit, it is important to take into consideration the minimum bend radius and trace width to avoid shorting or overheating. It is also a good idea to include strain relief features in areas where the circuit will be subjected to stresses and strains, such as curves or loops. Lastly, it is helpful to add tin or soft gold finishes to the ends of the traces, as this will improve longevity and reduce the risk of corrosion.

Flex and rigid-flex circuits are an ideal solution for aerospace applications, as they can handle extreme temperatures and vibrations. In addition, they can take on different shapes that would be difficult to achieve with rigid PCBs, making them well suited for aircraft and satellite systems.

If you’re interested in implementing flex circuits in your next design, contact Avanti Circuits to learn more about our services. We are an industry leader in custom electronics and can help you unlock the full potential of flex circuits for your unique application.