Tools/Flex Circuit Calculator

Flex Circuit Calculator

Calculate bend radius and flex life for flexible PCBs

Flex Circuit Parameters

Number of Copper Layers

Copper Thickness (oz)

Polyimide Base (μm)

Coverlay Thickness (μm)

Expected Flex Cycles

Analysis Results

Not recommended for dynamic flex

Min Bend Radius

4.63

Total Thickness

μm

Strain Margin

3.0×

safety

Bend Factor

50×

thickness

Surface Strain

1.000%

Copper

17.5 μm

Neutral Axis

46 μm

Estimated Flex Life: ~6.3e+2 cycles at minimum bend radius

Flex Circuit Design Guidelines

For Dynamic Flexing

• Use 1/2 oz or thinner copper
• Route traces perpendicular to bend
• Use curved traces, not 90° angles
• Stagger traces across flex zone
• Avoid vias in flex area
• Use rolled annealed (RA) copper

For Static Bends

• Up to 1 oz copper acceptable
• Maintain minimum bend radius
• Support flex during assembly
• Consider bend relief cuts
• Use adhesive for strain relief
• ED copper acceptable

Per IPC-2223: Dynamic flex requires bend radius of 100× thickness minimum. Static bends (one-time installation) can use 6× thickness for single-layer, 12× for double-layer circuits.

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