Rigid-Flex PCB Manufacturing: Design Guide, Pricing & How to Order

Published June 10, 2026 · By Mayio Engineering Team · 9 min read

Your phone has one. Your smartwatch has one. Your hearing aid has one. Rigid-flex PCBs are the technology that makes modern compact electronics possible — they combine rigid circuit boards with flexible interconnects in a single, integrated assembly.

What Is Rigid-Flex?

Rigid-flex PCBs are hybrid boards that bond rigid FR4 sections with flexible polyimide sections. The result is a single board that can fold into a 3D shape — eliminating connectors, cables, and the reliability problems they cause.

Rigid sections — Where components are mounted (same as a standard PCB)
Flex sections — Thin, bendable areas that connect rigid sections
Bend zones — Where the flex layer transitions between rigid sections

Why Use Rigid-Flex?

Benefit	Impact
Fewer connectors	Higher reliability, fewer failure points
Smaller form factor	Fits into compact, 3D product enclosures
Lighter weight	No cables or connectors = less mass
Better signal integrity	Fewer impedance discontinuities
Improved vibration resistance	Continuous board vs loose cables

Common Applications

Smartphones & tablets — Connecting display, battery, camera modules
Wearables — Wrapping around wrist curvature
Medical devices — Implantables, hearing aids, endoscopes
Aerospace & defense — High-reliability, vibration-prone environments
Automotive — Dashboard displays, sensor arrays
Industrial cameras — Compact sensor-to-processor connections
LED lighting — Curved LED strips and panels
Robotics — Joints and articulating sections

Layer Stackup Options

Stackup	Description	Complexity	Cost
2-layer rigid + 1-layer flex	Simplest rigid-flex	Low	$$
4-layer rigid + 2-layer flex	Most common for consumer electronics	Medium	$$$
6-layer rigid + 4-layer flex	High-density, complex routing	High	$$$$
8+ layer rigid + multi-layer flex	Mil-spec, medical, aerospace	Very High	$$$$$

Design Rules for Rigid-Flex

1. Bend Radius

Static bend (one-time): Minimum radius = 6× flex thickness
Dynamic bend (repeated): Minimum radius = 12× flex thickness

2. Copper Routing in Bend Zones

Route traces perpendicular to the bend axis
Use curved corners, never 90° angles
Keep copper weight thin (0.5oz) in flex areas
Use hatched pours instead of solid copper

3. Stiffeners

FR4 stiffeners for component mounting areas
Polyimide stiffeners for ZIF connector tails
Place stiffeners on the opposite side of components

4. Transitions

The rigid-to-flex transition is the most critical area
Use generous fillets at the transition edge
No vias or pads within 1mm of the transition
Coverlay should extend into the rigid section by at least 2mm

5. Drill-to-Edge Distance

Keep drills at least 0.5mm from any flex edge
Prefer mechanical drills (0.2mm+) over laser drills in flex areas

Rigid-Flex PCB Pricing

Configuration	5pcs	10pcs	50pcs	Lead Time
2L rigid + 1L flex	$20	$35	$120	10-12 days
4L rigid + 2L flex	$35	$60	$220	12-14 days
6L rigid + 4L flex	$60	$110	$400	14-21 days
8L+ rigid + multi flex	Quote	Quote	Quote	21+ days

Important: Rigid-flex pricing depends heavily on the number of flex layers, bend zone count, stiffener requirements, and panelization efficiency. Send your Gerber files and stackup drawing for an accurate quote. The prices above are for standard configurations.

How to Order Rigid-Flex PCBs

Design your board in KiCad/Altium with rigid and flex layers clearly defined
Create a stackup drawing showing layer counts, materials, and thickness for each section
Export Gerbers including all rigid and flex layers
Send files + stackup drawing to your manufacturer
Get DFM review — rigid-flex requires more review than standard boards
Approve, pay, wait — typically 10-21 days for fabrication

Get a Rigid-Flex Quote

Rigid-flex PCBs require careful engineering review. Send us your Gerber files and stackup drawing — we'll review the design, suggest optimizations, and provide an accurate quote with all-in pricing.

💬 Send Rigid-Flex Files on WhatsApp