Rigid-Flex PCB Manufacturer & Supplier – High-Performance Boards

Rigid-Flex PCBs: Advanced Manufacturing Services

At Sierra Assembly, we specialize in rigid-flex PCB manufacturing and design, providing reliable and high-performance solutions for a wide range of industries. Our expertise combines rigid PCB fabrication with flexible printed circuit board (PCB) technology, allowing us to deliver high-quality rigid-flex circuit boards tailored to your specifications. Whether you need fast turn rigid flex PCB production or complex multi-layer designs, Sierra Assembly is your trusted rigid-flex PCB manufacturer in the U.S.

What Are Rigid-Flex PCBs?

Rigid-flex PCBs are circuit boards that combine both rigid and flexible sections into a single assembly. The rigid areas provide mechanical support and hold components, while the flexible areas connect multiple rigid sections, allowing for dynamic movement, space optimization, and weight reduction.

Rigid Sections: Provide stability for components and connectors
Flexible Sections: Made with material for flex PCB such as polyimide, enabling bending without damage
Permanent Integration: Rigid and flexible layers are permanently combined during fabrication

At Sierra Assembly, we manufacture both custom asymmetric rigid-flex PCBs with outward flexible layers and symmetric designs with inward flexible layers, meeting precise application requirements.

Why Rigid-Flex PCBs Matter

Using rigid-flex PCBs offers several advantages over standard rigid or flexible boards:

Streamlined Assembly: Combines multiple boards into a single assembly, simplifying rigid PCB fabrication and flex circuit board manufacturers processes.
Fewer Solder Joints: Reduces failure points and improves reliability.
Space and Weight Savings: Enables compact, lightweight designs ideal for modern electronics.
Cost Efficiency: Reduces total PCB assembly costs by integrating multiple layers into one board.
Enhanced Durability: Flexible sections absorb mechanical stress, extending product lifespan.

These advantages make rigid-flex PCBs suitable for industries that demand high performance, reliability, and miniaturization.

Sierra Assembly’s Rigid-Flex PCB Manufacturing Capabilities

At Sierra Assembly, our rigid-flex PCB fabrication capabilities include:

Specification	Capability
Layer Count	2 – 10 Layers
Materials	Polyimide, FR4
Copper Thickness	9 µm, 12 µm, 18 µm, 35 µm
Minimum Line/Spacing	125 µm / 125 µm
Smallest Drill	0.28 mm
Surface Finishes	Immersion Ni/Au, OSP, Plated Ni/Au, Immersion Tin
Stiffener Materials	FR4, Steel, Aluminum
Min. Annular Ring	150 µm
Min. Soldermask Dam	100 µm
Drill to Copper – Outer Layers	8 mil
Drill to Copper – Inner Layers	10 mil
Minimum Pitch	0.5 mm
Copper to Board Edge	0.007″
Minimum Hole Size	0.004″
Coverlay Opening	0.003″

This allows us to manufacture high-density rigid-flex boards that are both durable and lightweight, while meeting precise design tolerances.

Our Rigid-Flex PCB Manufacturing Process

At Sierra Assembly, we follow a thorough and precise process to ensure every rigid flex PCB meets your specifications and performs flawlessly. From initial design consultation to final testing, each step is carefully managed by our experienced engineering team.

1. Design Consultation

Our process begins with an in-depth design consultation. We work closely with your engineering team to review your project requirements and understand the intended application. During this stage, we consider:

Layer configuration and board complexity
Component placement and density
Mechanical and thermal requirements
Flexibility needs and bending radii

This step ensures your design is optimized for both performance and manufacturability, reducing the risk of errors later in the process.

2. Material Selection

Selecting the right materials is critical for flexible printed circuit boards and rigid sections. Our team recommends the most suitable material for flex PCB and rigid layers based on your design, electrical requirements, and durability needs. Options include:

Polyimide for flexible layers: Heat-resistant, durable, and capable of repeated bending
FR4 for rigid layers: Provides stability, strength, and reliable component mounting
Copper thickness options: 9 µm, 12 µm, 18 µm, 35 µm depending on current requirements
Surface finishes: Immersion Ni/Au, OSP, Plated Ni/Au, or Immersion Tin

By carefully selecting materials, we ensure your rigid flex PCB manufacturing is optimized for long-term performance.

3. Prototyping

Before full-scale production, we offer flex PCB prototyping to validate your design. During prototyping, we:

Fabricate a small batch of boards to test electrical and mechanical performance
Check the bending and flexing capabilities of flexible sections
Ensure component placement and routing are correct
Validate manufacturability for multi-layer rigid-flex designs

Prototyping allows for early detection of potential issues and reduces rework, saving both time and cost.

4. Production

Once the prototype is approved, we move into full-scale rigid flex PCB manufacturing. This includes:

Precise layering of rigid and flexible sections
High-accuracy drilling and routing for vias and component holes
Controlled lamination processes to permanently bond rigid and flexible layers
Application of surface finishes to meet electrical and soldering requirements
Integration of stiffeners or mechanical supports as needed

Our rigid flex PCB fabrication capabilities ensure that each board meets design specifications and industry standards.

5. Testing & Quality Assurance

Quality is our top priority. Every PCB undergoes rigorous testing and quality assurance to verify both electrical and mechanical integrity:

Electrical testing: Check for shorts, opens, and correct component placement
Mechanical testing: Validate bending, flexing, and stress tolerance
Visual inspection: Ensure proper solder mask, silkscreen, and overall board quality
Compliance with IPC, RoHS, and ISO standards for traceability and reliability.

Through this comprehensive process, we ensure that every flex rigid PCB manufacturer project delivered by Sierra Assembly is fully functional, reliable, and ready for your application.

If you’re planning a rigid-flex PCB and want expert guidance from design through production, request a quote from Sierra Assembly today. Our engineering team will review your requirements and help ensure your board is optimized for performance, reliability, and manufacturability.

Rigid-Flex PCB Prototyping & Fast Turn Services

We understand the need for speed and accuracy in product development. Our flex PCB prototyping and fast turn rigid flex PCB services help clients bring products to market quickly without compromising quality.

Prototype runs for design verification
Quick turnaround for pilot production
Custom specifications supported, including unusual flex circuit fabrication requirements

Our team of experts ensures each rigid-flex PCB supplier project meets the highest quality standards before moving into full-scale production.

Benefits of Choosing Rigid-Flex PCBs

Benefit	Description
Simplified Assembly	Fewer connections and solder joints, improving reliability
Space Efficiency	Flexible sections reduce package size and weight
Cost Savings	Reduces overall manufacturing and assembly costs
Durability	Flex layers absorb mechanical stress for longer life
Design Flexibility	Enables compact designs for advanced electronics

By integrating rigid-flex PCB manufacturing into your design, you optimize both performance and reliability.

Applications of Rigid-Flex PCBs

Rigid-flex PCBs are widely used across industries that require compact, durable, and high-performance circuit boards:

Consumer Electronics: Digital cameras, smartphones, wearable devices
Aerospace & Defense: Avionics, military weaponry systems
Medical Devices: Diagnostic equipment, monitoring devices
Automotive: Telematics, advanced driver-assistance systems

At Sierra Assembly, we have extensive experience designing and producing flex circuits manufacturers solutions for these sectors, ensuring every project meets exact specifications and delivers reliable performance.

Why Choose Sierra Assembly for Rigid-Flex PCBs

At Sierra Assembly, we’re recognized as a top rigid flex PCB manufacturer because we blend technical expertise with a strong focus on customer needs. With years of experience in rigid-flex PCB fabrication and assembly, we deliver solutions that are both precise and reliable. We offer customized designs to meet the unique requirements of your projects, ensuring every board performs exactly as intended.

Our commitment to quality assurance means every PCB undergoes rigorous testing and inspection, fully compliant with IPC and ISO standards. Plus, with our fast turn rigid flex PCB capabilities, we provide quick prototyping and production without compromising quality. Our engineering team collaborates closely with each client to deliver high-performance rigid flex PCB supplier solutions that consistently exceed expectations.

Partner with a proven rigid-flex PCB manufacturer that delivers precision, speed, and reliability. Request a quote from Sierra Assembly today and let our engineering team turn your design into a high-performance rigid-flex PCB on time and to spec.

PCB Fabrication

Quick Contact

Rigid Flex PCBs