Understanding Circuit Card Assemblies (CCAs) and Flexible PCBs

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What Are Circuit Card ?

Circuit card assemblies, commonly kno+wn as PCB assemblies (PCBAs), involve connecting the wirings of PCBs with electronic components. These CCAs are created by the traces etched onto copper sheets of PCBs. They play a crucial role in various electronic devices, from smartphones to industrial machinery.

The Role of Flexible PCBs

Flexible PCBs, also called flex circuits, are designed to be highly adaptable. Unlike rigid PCBs, which are inflexible and have fixed shapes, flex PCBs can bend, twist, and conform to irregular surfaces. Their flexibility makes them ideal for applications where space is limited or where the board needs to fit into non-traditional shapes.

Circuit Card Assemblies (CCAs) and Flexible PCBs

Factors Affecting Flexible PCB Cost in Circuit Card Assembly

1. Labor Costs

The labor costs of PCB assembly are influenced by the geographical location where the circuit boards are manufactured. Skilled human processes and automated machinery contribute to these costs. For instance:

  • PCB assembly in South Asia is generally more cost-effective than in North America or Western Europe.

  • A three-day turnaround time for assembly in North America can cost around $1,100, while the same quantity of circuit boards in the People’s Republic of China costs approximately $545. However, overseas manufacturing may incur additional expenses due to shipping, handling, and communication delays.

2. Turnaround Time

The expected turnaround time significantly impacts the cost. Faster turnarounds may incur higher costs due to expedited production.

3. Quantity

The number of PCBs required affects the overall cost. Economies of scale come into play—the more units produced, the lower the cost per unit.

4. PCBA Board Assembly Method

Different assembly methods (such as surface-mount technology or through-hole technology) influence costs.

5. Technology

Advanced technologies (e.g., multilayer boards, high-frequency designs) may increase costs.

6. Parts Packaging

How components are packaged (reels, trays, tubes) affects assembly efficiency and cost.

7. Board Size and Layers

Larger boards or those with more layers may cost more.

8. Soldering Process

The type of soldering used impacts costs.

9. Testing Requirements

Testing procedures add to the overall cost.

10. Location of Assembly

Local vs. overseas assembly affects expenses.

11. Board Design

Well-optimized designs can reduce costs.

Typical Cost Range

Most PCB assembly unit costs fall between $10 and $50, depending on the number of units produced. Keep in mind that this is a rough estimate and doesn’t include all tooling and setup charges. The actual cost can vary widely among printed circuit board manufacturers.

Saving Money on PCB Assembly

To reduce costs, consider the following strategies:

  • Optimize PCB design to minimize wasted space and improve manufacturability.

  • Estimate PCB layout accurately to avoid unnecessary expenses.

  • Create a comprehensive bill of materials (BOM) to streamline procurement.

  • Be mindful of order quantity and timing to benefit from economies of scale.

  • Invest in thorough inspection and testing to prevent costly rework.

In conclusion, understanding the factors affecting flexible PCB costs and making informed decisions during circuit card assembly can lead to cost-effective and efficient production.

Advantages of Flexible Printed Circuit Boards (PCBs):

  1. Flexibility and Adaptability:

    They can adapt to small or irregularly shaped spaces, which is not supported by standard rigid circuits.

  2. Lightweight and Thin:

    Flexible PCBs are lighter and thinner than traditional rigid boards. This makes them ideal for integration into small devices or flexible materials.

  3. Resistance to Heat and Vibration:

    Flex circuits are more resistant to heat and vibration, making them suitable for challenging environments such as cars and airplanes.

  4. Space-Saving Design:

    By replacing traditional wiring, flexible PCBs allow for a considerable reduction in space, weight, and costs compared to equivalent solutions based on rigid PCBs.

    They have replaced many hand-wired connections, reducing the total cost of electrical wiring by up to 70%.

Applications where flexible PCBs have made a significant impact:

  1. Wearable Electronics:

    Fitbit Fitness Tracker: Fitbit utilizes flexible PCBs to integrate sensors, display components, and wireless connectivity in a slim and comfortable wristband. The flexibility of the PCB allows it to conform seamlessly to the user’s wrist.

    Smart Clothing: Smart shirts, sports bras, and other wearables incorporate flexible PCBs with sensors for tracking biometric data during physical activities.

  2. Automotive Industry:

    Tesla Model S: The infotainment system in the Tesla Model S employs flexible PCBs. These PCBs integrate touchscreens, control panels, and audio components into a sleek dashboard design, enhancing user experience and safety.

    Automotive Lighting Systems: Flexible PCBs enable curved and contoured lighting elements, enhancing visibility and aesthetics.

  3. Aerospace and Defense:

    CubeSats: Small satellites often use flexible PCBs due to their lightweight and compact nature. These PCBs allow integration of sensors, transmitters, and power management systems while adhering to strict size and weight constraints.

    Avionics Systems: Flexible PCBs provide reliable interconnections in tight spaces and withstand harsh flight conditions.

  4. Consumer Electronics:

    Samsung Galaxy Fold: This smartphone utilizes flexible PCBs to e

    nable its folding display mechanism, offering improved durability and sleek design.

  5. Medical Instruments

    Hearing Aids: Flexible PCBs withstand wear and tear, making them suitable for hearing aids.

    Implantable Medical Devices: These devices benefit from the lightweight and adaptable nature of flexible PCBs.

  6. Industrial Machines and Robotics:

    Industrial Automation: Flexible PCBs find applications in robotics, automation, and control systems due to their space-saving design and durability.

  7. Telecommunications:

    Cell Towers and Base Stations: Flexible PCBs are used in communication infrastructure for their reliability and compactness.

  8. Consumer Electronics:

    LCD Displays: Flexible PCBs are essential for connecting LCD displays in devices like smartphones, tablets, and TVs.

What are the challenges in manufacturing flexible PCBs?

Manufacturing Flexible Printed Circuit Boards (PCBs) presents several challenges due to their unique properties. Let’s explore these challenges in detail:

Material Selection:

Choosing the right substrate material is crucial for flexible PCBs. Common substrates include polyester films, polyimide (PI) films, and polytetrafluoroethylene (PTFE).

Material selection impacts flexibility, durability, and cost1.

Design and Layout:

Designers must consider bending radius, folding methods, and connections to other components.

Ensuring that the layout accommodates flexing without compromising functionality is essential.

Manufacturing Accuracy:

Handling thin and flexible substrates during manufacturing requires precision.

Aligning layers accurately to maintain electrical connectivity is challenging.

Reliability and Durability:

Flexible PCBs experience stress during bending, which can lead to fatigue and failure over time.

Ensuring reliability at fold points is critical.

Vias and Holemaking:

Drilling holes (vias) in flexible PCBs without damaging the delicate substrate is challenging.

Mechanical or laser drilling methods must be precise.


Depositing metal onto the surface of the board (plating) affects conductivity and corrosion resistance.

Achieving uniform plating thickness across flexible surfaces is complex.

Transfer Printing:

Transferring patterns from the PCB to a film involves heat or cold transfer methods.

Ensuring proper alignment and bonding without damaging the flexible material is a challenge.

Cost Control:

Balancing material costs, manufacturing processes, and reliability is essential.

High-quality flexible PCBs can be expensive to produce1.

Handling and Storage:

Flexible PCBs are delicate and require careful handling during assembly and storage.

Proper storage conditions are crucial to prevent damage.

Repair Complexity:

Repairing damaged flexible PCBs is challenging due to their intricate design and delicate materials.

Repairs can be costly and time-consuming.

Material options for flexible substrates

1.Polyimide (PI):

Polyimide is the most prevalent material choice for flexible PCB substrates. It offers several advantages:

  1. High Flexibility: PI is very flexible, allowing it to withstand bending and twisting without damage.

  2. Toughness: It is tough and resistant to tearing or stretching.

  3. Heat Resistance: PI can handle multiple solder reflow cycles due to its high heat resistance.

  4. Stability: It remains stable during temperature fluctuations.

PI is widely used in various applications, including wearables, automotive electronics, and aerospace systems12.

2.Polyethylene terephthalate

Polyethylene Terephthalate (PET):

  1. PET is another common material for flexible circuits.

  2. It is less heat-resistant than PI, making it suitable for applications where soldering is not required.

  3. PET is used in low-cost electronics and products with printed conductors2.

3.Polyethylene naphthalate

Polyethylene Naphthalate (PEN):

  1. PEN is similar to PET but offers better heat resistance.

  2. It is used in applications where higher temperature tolerance is necessary3.


  1. Parylene is a conformal coating material that provides excellent moisture and chemical resistance.

  2. It is often used as an encapsulation layer for flexible PCBs1.


  1. PDMS is a silicone-based material known for its flexibility and biocompatibility.

  2. It finds applications in medical devices and wearable sensors4.

6.Other Materials:

  1. Alumina: Used for high-power and microwave applications.

  2. FR-4: Although not as flexible as the others, FR-4 is sometimes used for simple assemblies.

  3. Ceramic Materials: Used in specialized cases.

In summary, the choice of flexible substrate material depends on factors such as flexibility requirements, heat resistance, and specific application needs. Polyimide remains a popular and versatile choice for most flexible PCBs。