The question not asked may be cause for concern.

It is essential for PCB fabricators to ask their customers engineering questions before production. Clarifying design requirements and expectations ensures they are fully understood, preventing costly errors, avoiding liberties being taken in the fabrication process, resulting in a product that meets both performance and reliability standards.

I write this not only to set clear expectations for customers but to strongly caution that when questions are not asked, there may be cause for concern. Questions must be asked so we can align objectives. The PCB is custom manufactured, and in many cases, the fabricator is either replicating something another manufacturer has built or creating something entirely new. In both scenarios, setting clear expectations is critical. If someone else has built it, we must know what we’re matching. Conversely, if the part number is a first-time build, the customers must understand that we’re doing something that has not been achieved.

Why a relatively unknown technology might be right for static bend applications.

Working with semi-flexible PCBs has opened some unique opportunities that I believe are worth exploring. The idea behind semi-flex is simple yet effective: a circuit that can flex without the high cost associated with using polyimide materials, which are typically necessary for full flexibility. This means the PCB can handle moderate bending without the expense of materials traditionally required for a fully flexible circuit. In multiple scenarios, once I’ve introduced this technology to customers, they’ve fully embraced it and have incorporated it into their PCB designs many times over, replacing rigid-flex designs for limited or static bend applications.

Despite the advantages, semi-flex is still a relatively unknown technology. A small group of people understand what it is and use it regularly, but for most, it’s completely new, and they’re often amazed by the possibilities it brings. Many customers light up when they see how a semi-flexible circuit could work in their applications, especially since it brings flex into the rigid realm. This permits flexible applications while leveraging the manufacturing techniques of a typical multilayer or HDI factory. It’s a major advantage because, unlike fully flexible PCBs, semi-flexible boards don’t require specialized facilities, which can drive up costs and narrow production options.