The PCBSync Rigid Flex PCB — 4-Layer Impedance-Controlled is a premium, production-grade circuit board engineered for engineers and product teams who need high reliability, precise signal control, and compact form factors — all in one board.
By integrating both rigid and flexible zones into a seamless stack-up, this board eliminates the need for separate connectors and flat flexible cables, reducing assembly steps, mechanical failure points, and total system weight by up to 60%.
Key Features
- 4-Layer Stack-Up: Two outer copper signal layers (1 oz) and two inner planes (0.5 oz) for optimal power distribution and ground shielding.
- Impedance Control on All Layers: Single-ended and differential-pair traces are TDR-verified to ±10% tolerance across every layer — critical for USB 3.x, PCIe Gen 3/4, MIPI CSI/DSI, HDMI, and high-frequency RF.
- Polyimide Flex Core (Kapton®): The flex region is rated for 100,000+ dynamic bend cycles, making it suitable for hinges, wearables, robotics, and deployable mechanisms.
- ENIG Surface Finish (default): Electroless Nickel Immersion Gold ensures flat, corrosion-resistant pads — optimal for fine-pitch BGA, QFN, LGA, and edge-connector footprints.
- IPC Class II / III Available: Full manufacturing documentation, TDR reports, impedance coupons, and cross-section analysis on request.
- Fast-Turn Prototypes: 5-day prototype and 15-day production lead times with dedicated engineering review for every order.
Technical Specifications
| Parameter |
Value |
| Layer Count |
4 Layers (Rigid-Flex) |
| Base Material |
FR-4 (rigid) + Polyimide / Kapton® (flex) |
| Controlled Impedance |
±10% (TDR verified) |
| Outer Copper Weight |
1 oz (35 µm) |
| Inner Copper Weight |
0.5 oz (18 µm) |
| Minimum Trace / Space |
3 mil / 3 mil |
| Minimum Via Drill |
0.2 mm |
| Surface Finish |
ENIG (standard) | HASL | OSP |
| Total Board Thickness |
0.8 mm – 2.4 mm |
| Flex Region Thickness |
0.10 mm – 0.30 mm |
| Operating Temperature |
-40°C to +130°C |
| IPC Standard |
IPC-6013, IPC-A-600 Class II / III |
| Bend Cycle Rating |
100,000+ (dynamic flex zone) |
| Prototype Lead Time |
5 business days |
| Production Lead Time |
15 business days |
Applications
This board is trusted across industries where reliability and compact design are non-negotiable:
- Consumer electronics — smartphones, tablets, laptops, smart displays
- Wearable and medical devices — ECG monitors, hearing aids, implantables
- Aerospace and defense — avionics, satellite payloads, missile guidance
- Automotive ADAS — radar modules, camera systems, in-cabin sensors
- Industrial automation and robotics — articulated arms, drones, AGVs
- IoT edge devices and handheld scanners
Why PCBSync?
PCBSync specializes in advanced PCB technologies with a focus on precision, traceability, and engineering support. Every Rigid Flex PCB order includes a free Gerber DFM review, impedance stack-up confirmation, and a dedicated account engineer — so your design gets to production right the first time.
Need a custom stack-up, different copper weights, or blind/buried vias? Contact our engineering team for a tailored quotation.
