Flex Circuit Education

What Are
Flexible Circuits?

A conductor that bends and flexes to fit into a range of electronics — enabling smaller, lighter, more capable products than rigid boards allow.

What Are Flexible Circuits?

Flex Circuit Fundamentals

What Is a Flexible Circuit?

GCA Flex manufactures circuits on flexible polymer film substrates — assemblies that conform to any shape and flex during use.

A flexible circuit is a conductor that bends and flexes to fit within electronic devices. Made using a thin polymer film — typically KAPTON polyimide — acting as an insulator, with copper conductors attached.

Gold or solder is used as a protective layer over the copper to prevent oxidation. What sets flex circuits apart is their ability to bend and flex — saving space and weight within electronic devices.

Flex circuits are made using photolithographic technology — the same precision process as rigid PCBs, applied to flexible KAPTON polyimide substrates instead of rigid FR-4.

What are flexible circuits GCA Flex

Application Categories

Three Ways Flex Circuits Are Used

Static Applications

Circuit is bent to shape during assembly and stays fixed. Used in cameras, compact electronics, 3-axis interconnections. Does not flex during normal use.

Dynamic Applications

Circuit flexes repeatedly during normal operation. Printer heads, disk drive arms, folding phones. Must withstand millions of flex cycles without failure.

Wire Harness Replacement

Replaces bulky wire harnesses between sub-assemblies. Used in cars, aircraft, and satellites. Space, weight, and reliability advantages are significant.

Circuit Types

Types of Flexible Circuits

All manufactured in-house by GCA Flex in Carson, California.

Single-Sided

One conductor layer. Most common and cost-effective. Up to 500M flex cycles. Learn more →

Double-Sided

Two layers — crossover connections and two-sided assembly. IPC Type II or V. Learn more →

Multilayer

3+ layers. Trace to .0015″. Microvia to .001″. Maximum density. Learn more →

Rigid-Flex

Hybrid rigid and flexible in one structure. Eliminates connectors. Learn more →

Sculptured

Variable conductor thickness via multi-step etching. Built-in contacts. Learn more →

Double Access

Single layer accessible from both sides. Specialty processing. Learn more →

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