Aerospace Flexible Printed Circuits

Amphenol Trackwise is a UK aerospace PCB manufacturer specialising in length-unlimited multilayer flexible printed circuits. Using our patented Improved Harness Technology™ process, flexible PCBs can replace conventional aircraft wiring harnesses, reducing weight, saving space and simplifying assembly in demanding aerospace and avionics applications.

Our roll-to-roll manufacturing capability enables power and high-speed signals to be carried across extended distances without the intermediate connections normally required by conventional flexible circuits.

Why Are Flexible Printed Circuits Ideal for Aerospace Applications?

Flexible multilayer PCBs offer significant advantages over conventional aerospace wiring harnesses, particularly where weight, space, reliability and assembly efficiency are critical.

By consolidating multiple wires and connection points into a single flexible printed circuit, aerospace manufacturers can reduce interconnect weight, simplify installation and improve production consistency. Trackwise’s patented roll-to-roll process also enables flexible multilayer PCBs to be manufactured across lengths that cannot be achieved through conventional panel-based production.

Length-Unlimited Multilayer Aerospace PCBs

Traditional flexible PCB manufacturing is often restricted by the dimensions of a fixed production panel. Trackwise overcomes these conventional panel-length limitations through a patented continuous roll-to-roll process, enabling long-length multilayer flexible PCBs to be manufactured for large aerospace and avionics applications.

Working panels can be produced in lengths of up to 100 metres and widths of up to 630mm, allowing a single flexible circuit to extend across large aerospace structures while reducing the need for multiple joined boards and intermediate connectors.

Trackwise has manufactured a flexible multilayer PCB measuring more than 72 metres in length, demonstrating the scalability of the technology. Long-length aerospace PCBs can support power distribution, data transmission and complex signal routing while remaining thin, lightweight and easy to integrate.

Capability	Available specification
Working panel length	Up to 100 metres
Maximum working width	Up to 630mm
Prototype layer count	Up to 8 copper layers*
Production layer count	Up to 4 copper layers*
Manufacturing process	Continuous roll-to-roll
Longest manufactured circuit	More than 72 metres
Maximum overall thickness	Up to 1mm
Signal capability	Power, data and high-speed signals
Key advantage	Fewer joins and intermediate connections

*Maximum layer counts are subject to circuit thickness and individual design requirements.

A Lightweight Alternative to Aircraft Wiring Harnesses

Conventional aircraft wiring harnesses can add significant weight, volume and assembly complexity to aerospace systems. Large bundles of individual wires may also require numerous connectors, clips and intermediate connections across wings, fuselages and other large structures.

Trackwise’s Improved Harness Technology™ can replace multiple individual wires with a thin, integrated flexible printed circuit. Power, data and control signals can be incorporated into a single long-length interconnect, reducing the number of components required and simplifying installation.

By consolidating complex wiring into a repeatable flexible PCB design, aerospace manufacturers can reduce weight, save space and minimise intermediate connection points while meeting the electrical requirements of the application.

Explore how Improved Harness Technology™ can replace conventional aerospace wiring.

Aerospace and Avionics PCB Applications

Amphenol Trackwise’s long-length multilayer flexible PCBs are suited to aerospace systems where conventional wiring harnesses create unnecessary weight, bulk or connection points. A continuous flexible circuit can be routed across large structures while carrying power, data and control signals within a thin, lightweight interconnect.

Aircraft Wing and Fuselage Interconnects

Long-length flexible circuits can extend across aircraft wings, fuselages and other large structures without relying on multiple joined boards. Reducing intermediate connectors can simplify routing, save space and remove potential connection failure points from the interconnect system.

Unmanned Aerial Vehicles

Weight reduction is particularly valuable in unmanned aerial vehicles, where lower system mass can support increased payload, range or operating efficiency. Trackwise has supplied a 26-metre multilayer flexible circuit used to distribute power and control signals across the wings of a solar-powered UAV.

Avionics Power and Signal Distribution

Flexible PCBs can combine power, data and control connections within a single integrated circuit. They can also be designed to support LVDS and differential signal routing, providing an alternative to separate twisted-pair cabling in suitable avionics applications.

LVDS and Twisted-Pair Flexible Circuits

If your project required LVDS, twisted pairs can be represented in length unlimited FPCs whilst maintaining all the benefits of traditional wiring including reduced AMI and improved signal integrity. 

You can find more information regarding replacing shielded twisted pairs with flex in our white paper. Alternatively, to speak to us directly about your project, get in contact.

Aerospace Quality, Certifications and Recognition

Quality, consistency and traceability are essential when manufacturing flexible PCBs for aerospace applications. Amphenol Trackwise operates a certified quality-management system designed to support repeatable manufacturing, documented processes and continuous improvement.

Our quality approvals and industry recognition include:

Certificates and further details about our quality approvals are available from our Document and Certification Downloads page.