Bringing Dance to Life with Flexible PCB Technology
Dance is art in motion—and great performance needs great gear. Partnering with a renowned Japanese product design firm, we developed a custom flexible PCB (FPC) solution for LED-enabled dancing shoes. This dynamic application required careful flex circuit design, focusing on bending radius calculations, optimal conductor routing, and glue layer control to ensure durability and flexibility.
Technical Highlights
| Parameter | Specification |
|---|---|
| Layers | 2-layer flexible PCB |
| Surface Finish | ENIG |
| Glue | Epoxy adhesive optimized for softness |
| Thickness | 0.15mm (without stiffener) |
| Copper Thickness | 2oz |
| SMT Service | LED assembly provided |
Bending Design Considerations:
- Maintain minimum bending radius based on flexible part thickness (dynamic: ≥25x thickness).
- Avoid vias and pads in bending areas.
- Use slots, drilled holes, and copper stiffeners for dynamic bending optimization.
- Stagger conductor traces between layers to reduce stress points.
Overcoming Production Challenges
The key difficulty was controlling glue-fill thickness while maintaining softness. After multiple iterations, our team selected a special epoxy glue blend that ensures consistent thickness and excellent flexibility—crucial for reliable dynamic bending in performance footwear.
Product Features
When fully charged, the shoes display multiple light colors that change frequency based on movement speed—creating a brilliant, interactive stage presence for dancers.
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