Custom Flat Flex Cable Solutions for High-Performance Electronics
Flat Flex Cables (FFC)
PICA designs and manufactures Flat Flex Cables (FFCs) for compact, high-speed, and space-sensitive applications. Built with precision flat copper conductors laminated between flexible insulating films, our FFCs provide a lightweight, reliable, and cost-effective interconnect solution for modern electronics.
From consumer devices and medical equipment to automotive systems and industrial controls, FFC assemblies enable tight-space routing, signal integrity, and fast production turnaround. With scalable manufacturing and engineering support, PICA delivers custom FFC cable assemblies that meet both performance and design requirements.
Space Efficiency – Ultra-slim, low-profile construction fits tight or irregular spaces where round cables cannot.
Flexibility – Easily bends, folds, and twists without damage, simplifying routing in compact electronics.
High-Speed Performance – Flat conductor geometry supports fast, reliable signal transmission.
Signal Integrity – EMI/RFI shielding options maintain performance in sensitive systems.
Cost-Effectiveness – Lightweight and streamlined, reducing bulk and lowering system costs.
PICA provides end-to-end FFC design, prototyping, and manufacturing with advanced options:
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Flat Flex Cable Capabilities
Technology
- Polyester (PET)
- Polyimide (PI)
- Adhesives: Epoxy, Acrylic
- Stiffeners: PI, PET
- Copper: Wire
- Foil Shielding
Materials
- Reliable Connection
- Highly Flexible
- Flexible and configurations
- Shielding Versions for EMI protection
- Gold-plated options
- RoHS, REACH, and UL rated
Interconnect
- ZIF/LIF connectors
- IDC: (Insulation Displacement Contact) connectors
- Hot Bar Soldering
- Crimp connectors
- Custom connectors
- Custom cable bending, folding, and punching
- Connector-to-cable assembly
- Hybrid cable solutions
- Shielding 1 or 2 sides
- Board-to-Board Assembly
Surface Finishing
- Unplated
- Tin plating
- Gold plating (ENIG)
- Custom plating options upon request
Shielding Options
Foil shields: Applied outside on one/both sides; may float electrically or connect to traces via IDC pins (1.27/2.54 mm) or drain wires for grounding.
Silver-epoxy shields: Applied on one/both sides with PET or conformal overcoat, or as full 360° coverage (<1 Ω) with trace/chassis connection through insulation openings; usable on all pitch sizes.
Copper foil tape: Conductive acrylic adhesive wrapped around cable for 360° shielding.
Process Capabilities*
| Pitch | p | 0.5±0.05 | 0.8±0.05 | 1.0±0.1 | 1.25±0.15 | 1.5±0.15 | 2.0±0.15 | 2.52±0.15 | P≤50 |
| Total Pitch | TP | P*(N-1) | |||||||
| ±0.08 | ±0.1 | ±0.15 | |||||||
| Width | W | P*(N+1) | |||||||
| ±0.08 | ±0.1 | ±0.15 | ±0.2 | ±0.2 | ±0.2 | ||||
| Margin | M | 0.5 | 0.8 | 1.0 | 1.25 | 1.5 | 2.0 | 2.54 | |
| ±0.08 | ±0.1 | ±0.15 | ±0.15 | ±0.15 | ±0.15 | ||||
| Total Length | TL | 20-10000, Min±1.5(≤50) | |||||||
| Insertion Thicknesses | IT | 0.3±0.03 | |||||||
| Insulation Thickness | INST | 0.1-0.4 | |||||||
| Conductor Strip Length | S1/S2 | ≤4±0.5, >4, <8±1; ≥8±2 | |||||||
| Supporting Tape Length | B1/B2 | ≤12±1; >12±2 | |||||||
| Conductor Thickness | Ct | 0.035, 0.05 | 0.035, 0.05, 0.1 | 0.05, 0.1 | 0.08, 0.1, 0.15, 0.2, 0.3 | ||||
| Conductor Width | Cw | 0.3 | 0.5 | 0.65 | 0.8 | 0.8 | 0.8/1.0 | 0.6/0.7 | 1.5/1.6 |
| Slanting | A1 | 0.5 | |||||||
| Stiffener | B | PET(0.16, 0.225, 0.25, 0.282) blue | |||||||
| PET+glue mm | 0.043, 0.06, 0.065, 0.08, 0.1 | ||||||||
| *Custom Configurations Available | |||||||||
Why Choose Flat Flex Cables (FFC)?
Space Saving – Ultra-low profile design fits where space is tight, enabling more compact and efficient devices.
Flexibility – Bends, folds, and twists without damage, conforming to irregular layouts and tight enclosures.
High Data Speeds – Supports rapid, reliable transmissions for high-performance electronics.
Signal Integrity – EMI/RFI shielding options protect against interference, ensuring cleaner, more reliable signals.
Cost-Effective – Streamlined and affordable interconnects, especially for high-density designs.
Markets We Serve with Flat Flex Cables
Consumer Electronics – Laptops, smartphones, tablets, cameras, and printers use FFCs for slim, reliable internal connections.
Industrial Machinery – Flexible cabling for automation, sensors, and displays—easy to install and maintain in complex systems.
Automotive – Internal wiring for displays, sensors, and modules that withstand vibration and temperature extremes.
Medical Devices – Compact, reliable interconnects in diagnostics, monitoring, and surgical equipment.
Defense & Aerospace – Lightweight, rugged FFCs for avionics, flight controls, and in-flight electronics.
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