Long-length Multilayer FPC Manufacturer
Overcome standard FPC length limitations. Utilising our patented Improved Harness TechnologyTM (IHT), Amphenol Trackwise manufactures continuous, roll-to-roll multilayer flexible printed circuits (FPCs) of any length to replace traditional wiring harness and cut weight by up to 75%.
Surpassing The Limits Of Traditional Flexible Circuit Technology
Many design engineers looking to implement long multilayer flexible printed circuits (FPCs) have been constrained by a hard manufacturing ceiling. Because traditional Printed Circuit Board (PCB) manufacturing relies on flat-bed, static panel processing, the maximum length of a standard off-the-shelf flexible circuit typically tops out at 30 to 50 cm (12 to 20 inches). Some manufacturers can produce circuits up to 30 metres (100 feet), but these are single and double-sided only, with multilayer circuits typically capping out at around 5 meters (16 feet).
When an application requires an interconnect to span 3 meters, 5 meters, or even 20 meters or 30 meters, engineers have traditionally been forced into one of two compromising design paths:
- Splicing and Connecting: Piecing together multiple short FPC panels using connectors or lap-soldering. This introduces unwanted weight, increases insertion loss, and adds multiple mechanical failure points.
- Reverting to Wire Harnesses: Abandoning flex entirely in favour of traditional bundled copper wiring, adding significant bulk, labour-intensive hand assembly, and severe weight penalties to the final build.
Amphenol Trackwise eliminates this compromise. By bypassing flat-panel restrictions entirely, we provide a globally unique capability: the manufacture of continuous, multilayer flexible FPCs of unlimited length.
Seamless Interconnects Without the Failure Points
Lighter
up to 60% weight saving
More repeatable
roll-to-roll mechanised process
Longer
length unlimited
Cheaper & Easier
to assemble
Smaller
up to 70% smaller
More Reliable
digital design / highly automated process
By extending the length of the circuit without introducing mid-run joins, Amphenol Trackwise allows you to map complex circuitry across the entire length of a vehicle chassis, aircraft wing, or industrial installation. This structural shift addresses three critical engineering priorities:
- Absolute Signal Integrity: Eliminating connectors means getting rid of the impedance mismatches, signal attenuation, and connection degradation common in segmented, long-run circuits.
- Unparalleled Reliability: In high-vibration environments, such as aerospace, UAVs, and electric vehicle battery packs, every physical interconnection is a potential point of failure. A single, unbroken long-length FPC removes these vulnerabilities entirely.
Drastic Weight and Space Savings: Replacing heavy, round wire bundles with an ultra-thin, planar FPC profile allows for space optimisation and up to a 75% reduction in interconnect weight, freeing up mass for extra payload or battery capacity.
Long Flexible PCB Manufacturing Capabilities & Specifications
To assist your design and engineering teams during the initial scoping phase, the table below outlines the core manufacturing limits and material options for our long flex circuits and length-unlimited flexible circuits.
Regardless of whether your project requires a straightforward point-to-point interconnect or a complex multilayer assembly utilising surface-mount technology (SMDs), these parameters define our standard roll-to-roll PCB manufacturing envelope.
|
Parameter / Capability |
Specification |
Engineering & Design Notes |
|---|---|---|
|
Pure Flexible Circuits (FPC) |
Length: Unlimited Width (Max): 600mm |
Manufactured in continuous rolls via our dynamic processing line. Eliminates mid-run joins. |
|
Base Substrate Materials |
Polyimide (PI), PTFE, PEEK) |
Substrates chosen for thermal performance and chemical resistance. Note: Not all materials are stocked in roll form; please contact us to verify availability. |
|
Conductor Materials |
• Copper • Aluminium • Nickel • Liquid Crystal Polymer (LCP) |
Standard copper weights support robust power/signal distribution. Aluminium options are available specifically for ultra-lightweight grounding (GND) applications. Note: Other conductors available for specific industries |
|
Circuit Configuration |
Single-sided, Double-sided, or Multilayered |
Supports complex, high-density routing across extended lengths without sacrificing flexibility or thickness constraints. |
Cross-Industry Applications for Continuous Flex Circuits
While eliminating length restrictions opens up possibilities across almost any electronic design, our continuous manufacturing capabilities are heavily relied upon by sectors where mass, reliability, and scale are critical.
Below is how our multilayer, long flex pcb expertise is leveraged to solve specific, high-stakes application constraints.
Aerospace & UAVs: Wing-Span Interconnects
In weight-critical aviation and unmanned aerial vehicles (UAVs), reducing standard cabling by even a fraction can drastically lower fuel costs and extend flight range. Amphenol Trackwise has manufactured continuous multilayer circuits stretching to route power and signals seamlessly across entire wingspans and fuselages without heavy, shielded twisted pairs.
Our aerospace multilayer FPCs solutions can lead to a 60% reduction in cable mass and complete immunity to connection failure points in high-vibration environments.
Automotive & EVs: Cell-to-Pack Battery Management
Modern alternative-fuel vehicle and EV manufacturers face massive architectural hurdles routing temperature, voltage, and control data through dense, cuboid battery enclosures. Our roll-to-roll process allows for full-length vehicle chassis runs and flat, planar configurations that map directly to the surfaces of EV battery modules.
Amphenol Trackwise’s automotive multilayer FPCs lead to streamlined space utilisation, automated assembly compatibility, and high-voltage power integration (up to 6oz copper) alongside control circuits.
Medical & MediTech: Minimally Invasive Instruments
The ongoing miniaturisation of advanced catheter-based and endoscopic equipment requires complex routing through incredibly tight, elongated spaces. Amphenol Trackwise adapts its continuous roll-to-roll technology down to microscopic scales, producing ultra-fine single and multilayer traces.
Our medical multilayer FPCs solutions offer seamless, continuous circuits of any length needed with precision trace and gap widths under 50μm, manufactured utilising biocompatible substrates.
Scientific & Industrial: Harsh Environment Sensing
From long-range infrastructure monitoring to subsea exploration, scientific and industrial FPC applications often require reliable data transmission across massive distances under severe environmental stress. We manufacture long FPCs designed to withstand extreme thermal windows.
Ready to Redefine Your Interconnect Architecture?
WHITE PAPERS
For more information regarding replacing shielded twisted pairs with flex, please visit our White Papers page to download the PDF.