Project Overview
Recently, our team received a challenging Rigid-Flex PCB project from an Indian customer. The board specifications included a 2-layer rigid-flex PCB, HASL finish, size 80x95mm, with a green solder mask and white silkscreen. The customer required not only PCB fabrication, but also PCB assembly (PCBA) and components sourcing. Due to the complexity, this project demanded additional planning, tooling, and strict quality control.
Challenges in Rigid-Flex PCB Assembly
The size of the rigid-flex PCB was relatively large for assembly, and the flexible section required reinforcement. While our factory has years of experience producing flexible PCBs and rigid PCBs (from 1 layer up to 12 layers), this was our first full rigid-flex PCB assembly project. To ensure success, our engineers, sales team, and factory manager held a detailed meeting to evaluate all customer requirements and discuss potential challenges.
One key issue was that the customer’s original Gerber file did not include a layout or reference marks. Without fiducial marks, it became difficult to fix the PCB securely on the assembly machine. Ideally, we should have requested permission from the customer to add layout marks, which would have made the process easier. Nevertheless, we had to find a solution.
Engineering Solutions
The project involved more than 10 different types of electronic components, which made manual assembly impractical. Our engineers proposed creating a custom jig. Thanks to our long-term partnership with a test fixture manufacturer, we were able to design a custom mold that securely fixed the rigid-flex PCB during the soldering process.
- Wave Soldering: With the jig in place, the rigid-flex PCB could pass through the wave soldering machine without shifting, ensuring precise component placement.
- Reflow Soldering: The board also required reflow soldering. Since the BOM included LEDs, we carefully adjusted the reflow oven temperature profile to meet the thermal requirements of sensitive LED components.
Trial Production and Mass Production
After finalizing the assembly plan, we started with a trial run of 3 prototype boards. The boards were tested by both our workshop team and engineers to ensure functionality and quality. Once the samples were approved, we moved forward with mass production. Every PCB underwent 100% testing before delivery.
The customer was highly satisfied with the final results, praising both the product quality and our professional handling of the complex assembly process. This success reaffirmed our belief that even with new challenges, our 12+ years of PCB manufacturing and PCBA experience allow us to deliver reliable solutions.
Our Commitment to PCB Projects
In the PCB industry, every project is unique. Some are straightforward, while others—like rigid-flex PCB assembly—require extra effort and problem-solving. While it is impossible for one factory to master every type of PCB immediately, we take pride in our willingness to take on challenging PCBA projects. With our technical expertise, dedication, and quality-first approach, we are confident in providing high-quality PCB and PCBA services.
Contact Us for Your PCB Needs
If you have a difficult PCB or PCBA project—whether it’s rigid-flex boards, multilayer PCBs, or complex component assembly—our team is ready to assist. Send us your Gerber files and BOM list today, and let us provide you with a professional solution.
Contact us now to request a quotation and start your PCB project with confidence!
