Rigid-Flex Board PCBA Project – From Challenge to Success

A New Challenge from Our Indian Customer

Recently, we received an exciting and challenging order from a customer in India. The project involved a Rigid-Flex PCB, with specifications of 2 layers, HASL finish, size 80mm x 95mm, and a green solder mask with white silkscreen.

But this wasn't just a PCB manufacturing order — the customer required a complete turnkey solution: PCB fabrication, component sourcing, and full assembly.

Understanding the Complexity

Compared to regular rigid or flexible PCBs, a Rigid-Flex Board poses unique challenges, especially in assembly. The board size was relatively large, and the flexible part required additional reinforcement to ensure mechanical strength.

Although our factory has rich experience assembling 1 to 12-layer rigid boards, as well as flexible PCBs, this was our first time assembling a Rigid-Flex PCB. To ensure a smooth process, we held an internal technical meeting involving our engineers, sales team, and production manager. We carefully reviewed all customer requirements and anticipated issues that could arise during assembly.

Design Oversight and a Practical Fix

During review, we discovered an oversight: the customer's Gerber files lacked a layout drawing and fiducial marks. Unfortunately, we did not clarify this point before production. Without the marks, the board was hard to fix accurately on machines during assembly — a mistake on our part.

However, we quickly came up with a solution. Our engineer proposed making a custom assembly jig. Thanks to our long-term partnership with a reliable test fixture supplier, we were able to quickly create a custom mold. This jig allowed us to securely fix the Rigid-Flex Board during wave soldering, ensuring components stayed in place and aligned correctly.

Special Care for Reflow and LED Components

In addition to wave soldering, the project also required reflow soldering. Since the BOM included several LED components, we had to pay extra attention to temperature control. Some LEDs are sensitive to high temperatures, so our team carefully adjusted the reflow oven settings to protect component integrity.

Trial Production and Quality Control

To minimize risk, we first produced three sample boards. These were jointly tested by our engineers and workshop technicians. After confirming that the samples met all quality standards, we proceeded with mass production.

Throughout the production process, we implemented 100% quality testing before delivery. The result? Our customer was very satisfied with the final product — and so were we.

Our Attitude Towards Difficult PCBA Projects

In the PCB industry, no two projects are the same. Some orders are straightforward; others are truly challenging. Even with over 12 years of experience, we know that there is always something new to learn.

We welcome the challenge. As long as we maintain our professionalism, experience, and dedication, we believe we can deliver high-quality PCBA products — even those we've never done before.

If you have a difficult PCB or PCBA project, we’re ready. Let’s make it happen — together.