How to Make Your Flex PCB LED Design into Reality?

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Flex PCB LED solutions keep expanding across industries as demand rises for products with creative shapes and compact structures. From automotive interiors to medical devices, these flexible boards blend functionality with space-saving benefits.

In this article, we’ll dive into what flex PCB LED means, explore its advantages, and share practical design and manufacturing processes. Whether you design products or source materials, this blog will help you understand why flex PCB LED continues to attract attention.

What is A Flex PCB LED?

A flex PCB LED is a thin, flexible circuit board designed to hold LED components while allowing the entire board to bend, twist, or fold during use. Unlike rigid PCBs, these boards are made from materials that stay reliable even after repeated bending.

Most flex PCB LED designs use polyimide or other flexible substrates that support surface-mount LEDs and small passive parts. These materials combine electrical performance with mechanical strength, helping the board withstand vibration and constant flexing without damage.

This flexibility helps designers install LED circuits into curved surfaces, folded product areas, or spaces too tight for traditional rigid boards. From flexible light strips to thin wearable screens, flex PCB LED technology supports creative designs while keeping circuits stable.

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What Are the Advantages of a Flexible PCB?

Flexible adaptability

With a bend radius of less than 1mm, it adapts to curved and irregular spaces, supporting dynamic three-dimensional bending in space (such as foldable screens, wearable devices).

Lightweight design

Thickness less than 1mm, light weight, space saving and improved portability, suitable for mobile phone backlighting, car interior and other scenarios.

High reliability

High temperature resistance (the PI substrate can withstand temperatures above 260°C), strong vibration resistance, dynamic bending life exceeding one million times, suitable for harsh environments such as mechanical arms and automobiles.

Integration and Precision Supports

Multi-layer circuit stacking, capable of integrating drive modules or sensors; high precision copper wires ensure stable signal transmission, suitable for high-density wiring requirements (such as medical endoscopes). Thermal Dissipation and Safety Excellent thermal conductivity reduces component thermal damage; overall wire connections reduce assembly errors, enhancing system reliability.

All Details You Need to Know About Flex PCB LED

What Are the Disadvantages of a Flexible PCB?

Higher Cost

Due to the use of polyimide substrates and precision etching processes, the production cost is significantly higher than that of traditional rigid boards.

Difficult to Repair

If the lines are damaged after bending on a flexible substrate, it is difficult to repair locally and usually requires a complete replacement.

Complex Design

It is necessary to reserve stress relief areas to avoid line fractures at the bend; special processes are required for connecting the soft and hard parts, which increases the development cycle. Installation

Restrictions

Sharp bends or excessive stretching should be avoided to prevent delamination of the substrate or fracture of the copper foil.

Limited Application Scenarios

High costs and process limitations make them more suitable for high-value-added fields (such as aerospace and high-end consumer electronics), making it difficult to popularize in the low-end market.

What Are the Different Types of Flex LED PCB?

Single-Sided Flex LED PCB

Single-sided flex LED PCBs have just one conductive layer, perfect for simple circuits with basic LED arrays. These boards work well for backlighting, light strips, or decorative LED products.

Double-Sided Flex LED PCB

Double-sided versions add a second conductive layer, helping designers create more complex LED circuits in the same flexible space. These boards suit products where LEDs need more control, like tunable lighting or segmented displays.

Multi-Layer Flex LED PCB

Multi-layer designs stack several conductive layers, allowing advanced routing and high-density LED layouts. These boards support smart lighting, automotive displays, or complex wearables where space-saving matters.

What Is the Difference Between Flex and Non-Flex PCB?

Material

Flex PCBs use polyimide, PET, or other bendable substrates, while non-flex PCBs use fiberglass (FR4) or other rigid materials. Flexible materials let the board bend without cracking.

Thickness

Flexible boards run thinner than rigid boards, especially in wearable or lightweight designs. Rigid boards tend to be thicker for strength and easier handling.

Applications

Flex PCBs often serve in curved lighting strips, medical devices, or foldable gadgets. Non-flex PCBs dominate in flat devices like TVs, computers and so on.

Assembly

Rigid PCBs handle easier during assembly since they keep their shape. Flexible boards need extra care to avoid creases or trace damage. However, when correctly handled, flex PCB LED boards work just as well.

What Are the Manufacturing Processes of Flex PCB?

1. Material preparation and pretreatment

Substrate cutting

Cut the polyimide (PI) or polyester (PET) substrate into specific sizes according to design requirements. The thickness of the substrate is selected according to the application scenario (13μm for dynamic bending area and 25-50μm for static area.

Drilling and hole metallization

Mechanical or laser drilling forms through holes for subsequent electrical connections; metallize the inner wall of the hole through chemical copper plating (PTH process) or electroplating process to ensure conductivity.

2. Circuit pattern production

Dry film coating and exposure

On the surface of the substrate The surface is covered with a photosensitive dry film, and the circuit pattern is transferred to the dry film through ultraviolet exposure.

‌Development and etching‌

Development removes the unexposed part of the dry film to expose the copper layer. Acidic or alkaline etching solution etches away the excess copper layer to form the target circuit.

Demolding and surface cleaning‌

Peel off the remaining dry film, and clean and activate the etched circuit.

3.‌ Overlay and protective film processing

Cover film lamination

Align the PI or PET covering film with the substrate, and the thickness of the covering film needs to match the bending requirements (bending area ≤25μm).

High temperature pressing

In a clean room environment, the cover film and the substrate are pressed together as a whole through high temperature (150-200℃) and high pressure (10-15MPa).

4. Surface treatment and functional enhancement

ENIG

Deposit a nickel-gold layer (0.5-2μm nickel + 0.05μm gold) on the pad area to enhance solderability and corrosion resistance.

Character printing

Print identification text or symbols in non-functional areas to facilitate subsequent assembly identification.

5. Functional testing and finished product processing

Electrical testing

Test the circuit conductivity through a probe, Detect defects such as open circuit and short circuit.

‌Auxiliary material assembly

Add PI reinforcement sheet or steel sheet at the joint of connector or hard board to improve mechanical strength. Attach auxiliary materials such as adhesive tape and electromagnetic shielding film.

Appearance cutting

Use mold stamping or laser cutting to divide the whole board into the final finished product size.

6. ‌Final inspection and packaging

Full inspection (FQC)

‌Perform a comprehensive inspection of the appearance, size and electrical performance of the finished product to eliminate defective products.

Packaging and storage

Store at low temperature (<10℃) after vacuum anti-static packaging to prevent moisture absorption or oxidation of the material.

What Are the Material of a Flex LED PCB?

Substrate layer

Material type:

Polyimide (PI) film must be used in dynamic bending scenarios, which has a temperature resistance of more than 260°C and a bending life of more than 500,000 times, and is suitable for high-reliability scenarios such as folding screens and wearable devices.

Polyester (PET) film can be used for low-cost static scenarios, but it has poor temperature resistance (<100°C) and a bending life of less than 50,000 times.

Thickness selection:

The dynamic bending area requires a 13μm ultra-thin PI substrate to reduce stress concentration.

The static area can use a 50μm thick substrate to improve mechanical strength.

Conductive layer

Copper foil type:

The dynamic bending area must use rolled copper foil (RA copper), which has excellent ductility (long bending life) and avoids fatigue fracture.

Static scenes can use electrolytic copper foil (ED copper) to reduce costs.

Copper thickness parameters‌:

Conventional copper thickness is 18-35μm‌.

High-frequency or high-density lines require ‌9μm ultra-thin copper foil‌ to reduce signal loss‌.

Covering layer and protective film

‌Material matching‌:

The covering film must be consistent with the substrate (such as PI substrate with PI covering film) to avoid delamination caused by differences in thermal expansion coefficient‌.

Thickness control‌:

The thickness of the covering film in the bending area is ≤25μm, and the non-bending area can be increased to 50μm for enhanced protection‌.

The adhesive layer needs to use ‌high-temperature curing epoxy resin‌ to support welding processes (such as reflow soldering)‌.

Adhesives and Stiffener materials

‌Adhesion performance:‌

A low-flow epoxy adhesive is required to ensure the interlayer bonding strength and prevent bending delamination‌.

Stiffener strategy:‌

PI stiffener sheets or steel sheets need to be added to the soft and hard joints to enhance mechanical support‌.

Dynamic structures such as sliding covers are recommended to use ‌glue-free electrolytic copper‌ (better ductility)‌.

Adaptation to special scenarios

‌High-frequency applications:

Polytetrafluoroethylene (PTFE) substrate is required to reduce dielectric loss.

Medical/wearable devices:

The cover film must have sweat-proof and chemical corrosion-resistant properties (such as medical-grade PI materials)

Surface treatment:

The pads in the dynamic bending area need to be plated with a thin nickel-gold layer (0.5-2μm nickel + 0.05μm gold) to prevent bending and cracking.

How to Design a Flexible PCB for LED?

1. Material selection and basic design

Substrate selection

Polyimide (PI) substrate is preferred, as its high temperature resistance (above 260°C) and bending resistance can meet dynamic bending requirements‌. If cost is sensitive and the temperature resistance requirement is low (<100°C), PET film can be used‌.

Conductive layer design

Rolled annealed copper is used instead of electrolytic copper foil to improve the fatigue resistance of the bending area. The copper thickness is recommended to be 18-35μm‌.

‌Coating layer optimization

The covering film should be a polyimide protective film that matches the substrate. The thickness of the covering layer in the bending area is ≤25μm to avoid cracking caused by bending stress concentration‌.

2. Key points of layout planning

‌Component layout rules

All components such as LED lamp beads and driver ICs must be arranged in the hard board area or static bending area, and the distance from the soft-hard combination boundary is >1mm‌48. It is forbidden to place components in dynamic bending areas (such as the joints of wearable devices), and PI reinforcement sheets should be added to improve mechanical strength when the bending radius is ≤3mm. ‌

Power supply partition design

A star power supply topology is used, and the power line width is ≥0.3mm (1A current) to avoid voltage instability caused by impedance mutation due to bending.

3. Wiring process and structural optimization ‌Line direction control‌

The routing in the bending area must be perpendicular to the bending axis, and arc corners (radius ≥1.5 times the line width) are used instead of right-angle routing to reduce bending stress. ‌

Multi-layer board stacking strategy

Single-sided wiring is recommended for dynamic application scenarios, and double-sided wiring (with a 0.05mm PI adhesive layer in the middle) can be used for static scenarios, and the total thickness is controlled within 0.2mm.

‌Transition zone treatment

The soft and hard combination parts adopt a gradient line width design (line width change gradient ≤20%), and add anchor points (Via-in-Pad) to prevent delamination.

4. Production process and test verification

Etching precision control

The line tolerance needs to be ≤±10%, and the line spacing in the dynamic bending area must be ≥0.2mm to avoid short circuit caused by micro crack extension‌.

Welding process selection

Use low-temperature solder paste (melting point 138℃) or conductive silver glue welding to reduce the damage of thermal stress to the flexible substrate‌.

Reliability test

Dynamic bending test: After 100,000 bends (radius 1mm/frequency 1Hz), the resistance change rate is ≤5%‌.

Environmental test: Continuous operation for 500 hours under 85℃/85%RH conditions without performance degradation‌.

5. Design tools and engineering implementation

‌EDA tool settings

Use the Rigid-Flex module of Altium Designer to divide the soft and hard areas by defining the dividing line, and set the bending radius parameters (recommended ≥3 times the board thickness).

‌3D simulation verification‌

Simulate the bending state in software such as SolidWorks to check the component collision risk and line tensile deformation (allowable tensile rate ≤ 0.5%).

Conclusion

To sum up, Flex PCB LED technology offers powerful benefits for modern electronics, supporting thin, lightweight, and creative lighting designs. These boards help engineers build curved, wearable, or space-saving products where rigid boards simply cannot fit.

With the right materials, careful design, and proper handling, flex PCB LED circuits bring both reliability and creative freedom to industries from automotive to medical. Whether you need simple lighting strips or complex LED arrays, flexible boards open new design possibilities.