The cost difference comes from the material used and the complexity of the tool making process. Hard tools are made from hardened steel and are made to precise tolerances. Due to the complex nature of manufacturing hard tools, the lead times can be anywhere from two to four weeks. Soft tools like steel rule-dies (SRD's) are made of plywood, embedded into which are semi-hardened steel blades. SRD's can be made in a couple of days.

Yes, flex is used in many high frequency applications, especially when a certain impedance is required on several signal traces. We are capable of designing artworks that have linewidths that meet customers' impedance requirements (within a given tolerance range). Furthermore, we can test the finished parts to verify the impedance values of each trace.

One of the disadvantages of flex is that once a part is made, it is very difficult to repair any electrical defects on the part. This would involve the time consuming process of removing the polymide insulation to access the electrical defect. Once the defect is repaired, a liquid soldermask would be applied to provide replacement insulation. The best alternative to this situation would be to remake the flex or replace with a defect-free flex.

Another disadvantage is that although a flex can be made very durable by using the proper stiffener supports, it needs to be handled carefully so as not to tear the flex, especially at areas where the flex outline has sharp corners or no tear stop relief features.

Our insulation materials are polyimide and our adhesives are acrylic and modified-epoxy. The copper is usually soft rolled-annealed (RA) or electro-deposited copper (ED), although RA copper is more commonly used.

In addition, we make single-sided flexible printed circuits using the lower-cost alternative, PET material.