Introduction
To understand the cost of Flexible Printed Circuit (FPC) prototyping, it’s essential first to grasp what an FPC is. FPCs are flexible circuit boards made from polyimide or polyester film as the base material. They are known for their high reliability, flexibility, high wiring density, lightweight, thin profile, and excellent bendability. With a clear understanding of FPCs, we can then delve into the factors that influence FPC prototyping costs.
What is FPC Prototyping?
FPC prototyping involves creating sample flexible circuit boards for testing and evaluation before mass production. The prototyping process is crucial in ensuring the design meets the required specifications and can be manufactured efficiently.
FPC Prototyping: Panel Design Standards
- Panel Frame Design:
The outer frame (holding edge) of the circuit board panel should be designed as a closed loop to ensure that the FPC panel remains fixed in the fixture without deformation.
- Component Clearance:
There should be no large components or protruding parts near the connection points between the panel’s outer frame and the individual small boards. Additionally, a clearance of more than 0.5mm should be maintained between components and the board edges to ensure the smooth operation of cutting tools.
- Positioning Holes:
Four positioning holes, with a diameter of 4mm ± 0.01mm, should be drilled at the four corners of the panel frame. These holes must have moderate strength to avoid breakage during the handling process. The diameter and position accuracy should be high, with smooth, burr-free hole walls.
- Small Board Positioning:
Each small board within the panel must have at least three positioning holes with a diameter between 3mm and 6mm. No wiring or surface-mounted components are allowed within 1mm of the edge positioning holes.
Calculating FPC Prototyping Costs
- Size-Based Pricing:
One common method is to calculate the price based on the size of the FPC. Manufacturers typically provide a per-square-meter rate, which varies depending on the number of layers and specific processes involved. To determine the price, customers can convert the dimensions of the FPC into square meters and multiply by the unit price. This method is suitable for standard FPCs with common processes.
- Cost-Refined Pricing:
Another approach involves detailed cost analysis. Since FPC materials primarily consist of copper-clad laminates (CCL), and CCL manufacturers offer fixed sizes in the market, the FPC manufacturer calculates the material usage based on the board’s design, number of layers, processes, and quantity. This method determines the material cost by calculating the utilization rate of the copper-clad laminates for the specific batch of FPCs.
Conclusion
It’s important to note that providing an exact price for FPC prototyping can be challenging due to the variability in design requirements and manufacturing processes. If you require FPC prototyping services, please contact Gekunflex. Gekunflex will provide you with a prompt and detailed quotation based on your specific needs.
