New-Tech Europe Magazine | Q1 2020

IHT is a roll-to-roll manufacturing process which not only enables the manufacture of multilayer FPCs of any length, but also, being machine intensive, makes it cost effective. In conventional FPC manufacturing, process steps including drilling, imaging, pressing and plating, are based on equipment that typically uses static processes. IHT uses specially adapted machinery and custom software to enable the dynamic processes required to manufacture FPCs of indeterminate length. Additionally, the IHT processes use materials in roll form, as opposed to the fixed size sheets which most materials are supplied in. Careful analysis and planning is required before embarking on any FPC implementation project. When specifying requirements, the customer must liaisecloselywiththemanufacturer to ensure that an FPC is actually suitable for the application. Also, in order to ensure that the end product performs as intended, a detailed design process should be followed, covering the end product requirements, the intended operating environment, package configuration, mechanical and electrical characteristics and assembly method. The output from this process will provide the specification required by the FPC manufacturer in order to validate the design and provide relevant quotations. With IHT, Trackwise is primarily targeting the replacement of conventional wire harnesses, where assembled components are limited to connectors. The long FPCs produced by the IHT process are however, essentially PCBs and can be populated with components, using either PTH or SMT techniques so as to produce a ‘smart’ harness.

Figure 2: Flexible circuits can replace complex wiring looms and be fitted neatly into or around car components, such as headlights or door frames.

Today, the automotive, aerospace and telecommunications industries are increasingly reaping the benefits of FPCs. Replacing large, heavy and complex wire harnesses, flexible

circuits are now used to meet the space and weight constraints of the growing number of in-cabin and on- board systems. In cars, for example, electronically-

Figure 3: A 26-metre long, multilayer flexible printed circuit for a UAV

28 l New-Tech Magazine Europe