Flexible PCB assembly for power cable

13 Sep, 2022

By ren

Things you need to know about Flexible PCB for power cable

Printed circuit boards (PCBs) are crucial to the general operation of electrical equipment. The layout of your flexible PCB assembly for power cable and the kind of cabling you choose will both affect how well it performs. The cable assembly and other parts you choose for your PCB will have a direct impact on how well your electrical system works.

Flexible PCB assembly for power cable

Despite how important PCB cable assembly is, many people prefer to see it as the last step in the process. The truth is that your cable assembly is made up of a variety of parts that influence the complete electrical system. For instance, connections decide if a gadget is compatible, while conductors decide how well electricity flows. As a result, you should pay more attention to how your flexible PCB assembly for power cable is implemented.

Flexible PCB

Flexible PCB, also known as Flexible Printed Circuit Board (FPCB) or simply FPC, is an extremely thin and very flexible printed circuit board that is constructed of a flexible plastic substrate, copper foil, and adhesive laminate. It may be used to paste wafers or SMT wafers on the board and is a lightweight, high accuracy, and capable of holding many layers of traces. To make the electronic product functional, the circuitry is often integrated with electronic parts including LEDs, IC chips, capacitors, and resistors. To enhance the functionality of flexible boards and cut down on power consumption, flexible PCB assembly for power cables continuously strives for better line densities and layer counts.

Gains from Flexible PCB

preserving space Since flexible PCBs are thin, bendable, and concave, they are often utilized for connections in applications where there is limited space and a high component density. Compared to a typical circuit board assembly, its design takes up just 10% as much room and weighs 10% as little, giving you more installation and packaging options.

Maximum Durability and Reliability. flexible PCB assembly for power cable necessitates fewer interconnects, which necessitates fewer contact crimps, connectors, and solder connections. Up to 500 million times without breaking, it can move and bend. It has fewer possible failure points, which increases its dependability and longevity.

Strengthened Abilities

 They are suitable for almost any kind of connection or component and function well with choices like a ZIP connector. Polyimide flex materials' excellent thermal stability allows them to work admirably at very high temperatures while also providing outstanding resistance to chemicals, radiation, and lubricants.

Cost reductions

 It decreased the need for materials and packing, the price of replacing components, and assembly mistakes that would need repairs.

Flex PCB types


 The most fundamental varieties of flexible boards are made up of a conductor layer covered in a bonding layer, then a dielectric layer. The production process is simple, and costs are reduced.


The circuit is created on a double-sided substrate, and when it has been completed on both sides, a covering film is placed on each side. The primary advantages of double Flex PCBs are more design freedom, space savings, and double-sided soldering.

Multilayer FPC:

 Mainly constructed of single or double panels that have been pierced to let the conductive layers flow through, boosting the circuit's density and enhancing dependability. enables more compact packages that are more adaptable in 3D designs with PTH, blind, and buried vias.

The most common rigid-flex circuit boards have numerous layers of flexible circuit substrates coupled to stiff boards externally and/or internally. Rigid-Flex PCB: FPC is squeezed together in series between two rigid PCBs to make one printed circuit board, which is known as a rigid-flex PCB. The flexible substrates are made to be always flexible and are often molded into a curved shape during production or installation. This depends on how the application is designed.

PCB assembly for flexible power cables

It takes careful consideration to choose the right parts for your cable assembly or wire harness. The following elements are crucial to the performance of your finished cable assembly.

1. Circuits are where it all begins.

Any cable assembly starts with a circuit or conductor network. These circuits, which are the main conduits for electrical flow, have a significant influence on performance. The conductive substance, stranding (to join several conductors), and plating make up a conventional circuit.

The preferred conductive substance is often copper. It works with many various kinds of coatings in addition to being reasonably priced. It may be applied to various cable assemblies to prevent corrosion and make current termination easier.

Copper is often coated with different materials to boost durability since it may be susceptible to corrosion. Additionally, alloys like copper-steel, copper-chromium, or copper-cadmium are employed when greater breaking strength is required.

You may choose either a single solid conductor or several thin strands of conductor depending on how your PCB is assembled. If you want to keep your PCB assembly flexible and not constrained by solid wires, utilize thin strands.

2. What kind of insulation will the cable assembly have?

You must decide how the cable assembly will be insulated after selecting an acceptable conductor. Thermoset and thermoplastic are the two main materials used for insulation. Your decision will be influenced by the conductors you're utilizing, the particular use for your product, and the make-up of your PCB assembly. When choosing an insulator material, you should additionally consider the following other criteria.

  • The range of temperatures your cable assembly will work in
  • Voltage ranges
  • Contact with chemicals and moisture
  • The external environment's nature

The underlying layers will be shielded from these external factors and will last longer with proper insulation. Fortunately, a wide range of materials is appropriate for a wide range of settings. To provide the greatest protection against chemical influence, you may even foam the insulating substance.

3. Shielding

Your cable assembly will often be subjected to electromagnetic fields. Therefore, to prevent performance drops, you need a material that can screen the conductors from interference. A thin metal foil that is kept together by polyester is the most cost-effective alternative. High frequencies may be effectively shielded by this material because of its extreme flexibility.

To eliminate electromagnetic interference, you may also construct a braided shield consisting of several small-diameter wires. Low-frequency effectiveness and great flexibility are two benefits of braided shielding.

Cable twisting is another issue to keep in mind. When twisting individual wires (in your assembly), you should choose a conductor that allows for effective current flow.

4. Choosing the outer jacket/sheath

The underlying cable assembly is safeguarded by the outer coating or jacket. It must be durable, fireproof, chemically impervious, and flexible enough to allow for simple movement. Depending on the particular use, certain outer coats also need to transmit electricity to a certain level.

You have a wide range of choices when it comes to choosing the right sheathing material:

  • PVC: affordable, widely used, and flexible
  • Fluorocarbon sheathing: great for preventing fires and also very durable
  • Elastomers are versatile, strong, and inexpensive.
  • Non-halogens: a favorable alternative for situations involving little acid and little toxicity

5. Which Connectors ought you employ?

Another choice to be made is connectors, which will affect overall compatibility. The performance will also be impacted by connectors, depending on the signal's speed and kind.

High-speed signal paths are more dependable when formed using welded connections. However, crimp connections will still work well for signals that are delivered via the actual assembly. These connections are also more adaptable since it is simple to switch them out depending on the device in use.

6. Certifications

Finally, you need to be aware of the mandatory safety requirements that apply to your cable assembly. Because different governing organizations run various nations, safety requirements will change depending on where you are.

Read more: HDI any-layer printed circuit boards


Among those well-known flexible PCB boards and FPC cable boards for connection manufacturers, EuropePCB Electronics is a skilled Flexible PCB assembly for power cable and FPC cable board for connection suppliers and factories. We can provide you with customized product pricing and quote consultation, so please feel free to purchase our goods at a discount.


Write to Us And We Would Be Happy to Advise You.

    l have read and understood the privacy policy

    Do you have any questions, or would you like to speak directly with a representative?