Flexible PCB's cost??

I am working on a custom vehicle (show car) project where I want to replace
the bulbs with an array of SMT LED's - I have very little space to work
with. I would like to be able to bend this array to match the contour of
the newly fabricated panels. Now I need to upgrade multiple bulb lights,
and rather than make multiple boards, I was thinking I could make a matrix,
and just trim it to size for each instance of use. Of course, I realize it
would require different resistor values, etc., thats no problem.

Can anyone give me a feel for the costs of getting flexible PCB's done vs.
plain old rigid PCB's? Let's say for qty 100 of a 4"x3" board. I'm not
looking for a quote - just a relative cost differential between flex and
rigid. There are no holes, no vias, single layer, 2 sided, about the most
basic board you could get made. If it's 50x as expensive as a comparable
rigid PCB, then I don't want to waste time getting people to price it.
Also, can you buy just the boards and assemble yourself, or is there
something that requires the manufacturer to also assemble them?

And second, is there any problem with cutting it in the way I mentioned
above? I mean is there any compromise to the board? Ideally I would trace
the shape on a piece of paper, then trim the board with sharp scissors to
match the contour I need. I know I'd need to "seal" the conductors on the
ends to prevent shorting. Am I nuts to even think it? Or is this
reasonable?

Thanks for any pointers!

S.L.

 

Any board house can give you a fairly accurate price comparison. Ask
the price difference on the dimensions given for FR4/062 v.s. Printed
Mylar. Depending the board house and whether or not they're already
set up to do flex the prices will vary. Try Brothers Union
International Corp in Santa Clara, CA. They have good prices and can
recommend layout strategies as well. Talk to Trish.

 

I'll give them a call - thanks!

 

Mylar boards will curve very nicely in a single dimension. They do not
curve real nicely in two dimensions... they tend to wrinkle if you try.
Very much like paper, in fact (although mylar is more critical.)

Cutting slots in the mylar can help make it bendable in the second
direction. I'd be very critical of doing this for a mass-produced
application, but for a show car that will never be abused by temperature
extremes it probably won't be so bad.

Tim.

 

I would suggest Lenthor Engineering in Milpitas California. They have been
making flex since the 80's and can quote you both rigid and flex.....