Rigid Flex PCB Manufacturer from 2 to 30 Layers

"Rigid-flex PCBs are a kind of advanced flexible PCBs that have flexible inner layers and FR4 external layers.
From PCBONLINE, you can buy rigid-flex PCB prototypes and massive manufacturing of 2 to 30 layers."
rigid-flex PCB

What is Rigid Flex PCB

Also known as semi-flex PCBs, rigid-flex PCBs belong to flexible PCBs but have rigid FR4 outer layers. The flexible PCB core, using polyimide or polyester laminates, have 1 to 6 circuit layers. The FR4 PCB layers attached on one or two sides of the flex core have 1 to 24 layers (at PCBONLINE). Different layers are interconnected with through-holes and microvias (buried, blind, staggered, stacked, etc.) Copper in a rigid-flex PCB's flex section must be rolled annealed (RA) copper, and PCBs for high-performance applications use high temperature and elongation (HTE) copper.
In rigid-flex PCB fabrication, we manufacture the flexible PCB first and laminate FR4 PCBs layers on the flex PCB. Then we cut off the unwanted rigid FR4 areas using the laser to expose the flex PCB coverlay. The exposed flex PCBs are the areas for bending.
PCBONLINE manufactures rigid-flex PCBs from 2 to 30 layers for automotive, medical, computing, communications, industrial, aerospace, and consumer electronics. If you don't need real rigid-flex PCBs but flex PCBs attached with stiffeners (FR4, polyimide, or stainless steel), it is also okay to fabricate them from PCBONLINE.

Rigid Flex PCB Available Structures

rigid-flex PCB structure
Rigid-flex PCBs provide dynamic and mechanical stability, freedom of 3D design, and reduced overall product space and weight. For these benefits, you can design rigid-flex PCBs with the below structures.
Symmetrical rigid flex PCB construction - the board is manufactured with inward symmetrical flex layers. Capability is from 3R+1F to 24R+6F.
Asymmetrical rigid flex PCB construction - the board is manufactured with outward asymmetrical flex layers. Capability is from 2R+1F to 24R+6F.
HDI multilayer rigid flex PCB construction - the board's rigid section is with blind/buried mirovias. HDI capability is 4+N+4.

Cost of Rigid Flex PCB

Except for the very easy 1-2 layer FR4 PCBs, all PCBs, including rigid-flex PCBs, are custom quoted by the PCB manufacturer after viewing your Gerber/PCB design files. The PCB price is determined by the laminate price, PCB layers, circuit complexity, surface finishes, and lead time. The unit price of massive PCB manufacturing is lower than that of PCB prototypes.
Rigid-flex PCBs are manufactured by laminating flexible and FR4 PCB layers, and the fabrication is much more complex than FR4 PCBs and flex PCBs. For this reason, rigid-flex PCBs are more expensive than FR4 PCBs and flexible PCBs. Usually, rigid-flex PCBs are 2 to 3 times costlier than flexible PCBs and 8 to 10 times costlier than FR4 PCBs.
Take 4-layer PCBs with a total area of 0.1 square meters as an example. At PCBONLINE, 4-layer rigid-flex PCBs cost about $900, while flexible PCBs cost about $450, and FR4 PCBs cost about $100. This is probably the most competitive rigid-flex price in the market.
PCBONLINE is a rigid-flex PCB source factory manufacturer and provides the most cost-effective and high-quality PCBs. By working with a reliable source factory manufacturer, you can save big than if working with a third-party trade company or agent.

Rigid-Flex PCB Certifications

Rigid-Flex PCB Certifications

Rigid Flex PCB Manufacturing Capabilities

rigid-flex PCB structure

Order rigid-flex PCBs from PCBONLINE for

  • applications that require flexibility and dense circuitry with compact spaces, such as
  • ● thermal imagers, automotive sensors, radar imaging systems, controller connection boards, etc.
  • ● satellite communications systems, smartphone/industrial cameras, lithium battery covers, etc.
  • ● medical devices like analytical instruments, capsule gastroscopes, health sensors, etc.
  • ● digital security controls, desktop/laptop screens, smart-wear devices, AI devices, headsets, etc.
PCBONLINE's Rigid Flex PCB Capabilities

Flex PCB layer number

1 to 6

Rigid-flex PCB layer number

2 to 30

Build time

1 day to 4 weeks

Board size

Min. 4mm × 4mm to Max. 457mm × 610mm

Final board thickness

0.05mm to 0.6mm


Polyimide or polyester, FR4 of any Tg, RA copper or HTE copper, and adhesive

PCB thickness in flex section

0.01mm to 0.1mm

PCB assembly Min. pitch


HDI PCB stack-up

1+N+1, 2+N+2, 3+N+3, 4+N+4

Aspect ratio


PCB copper thickness

1/3oz to 3oz

Min. trace width/space


Advantages of the One-Stop Rigid Flex PCB Manufacturer PCBONLINE

More than 20 years of experience in one-stop rigid-flex PCB manufacturing of 2 to 30 layers for the applications mentioned above
Comprehensive rigid-flex PCB testing for bending, anti-vibration, and other features according to application requirements
Strict quality control and ISO management system. Our PCB and PCBA manufacturing are ISO, IATF, RoHS, UL, and IPC certified.
We can optimize rigid-flex PCB design to be the most economical to lower your project fabrication price without quality sacrifice
You can avail of our professional one-on-one engineering support and free design for project manufacturing
Turnkey rigid-flex PCB services including PCB design, PCB fabrication, PCB assembly, electronic parts, and value-added services

We are solution experts to rigid-flex PCB projects
Contact our team here

Rigid Flex Pcb Manufacturing

Rigid Flex PCB Examples

"I ordered quite a lot rigid-flex circuit boards from PCBONLINE and they gave discounts for this order. Their reasonable prices and high manufacturing level will make this company become a leader in this industry."

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