Flexible PCBs are widely used in modern electronics due to their lightweight, space-saving, and bendable characteristics. A key component in flex PCB design is the coverlay, which serves as the protective insulating layer that shields the copper circuitry from moisture, chemicals, and mechanical damage.
In 2025, the cost of flexible PCB coverlay has become a more prominent consideration due to rising raw material and labor costs. This guide breaks down how much flexible PCB coverlay really costs and what factors influence the price.
1. What Factors Affect Flexible PCB Coverlay Price?
The price of coverlay in flexible PCB manufacturing depends on several variables:
- Material Type – Polyimide film, adhesive type, and temperature resistance level
- Thickness – Standard thickness ranges from 12.5μm to 50μm
- Design Complexity – Number of cutouts/windows, size, and tolerance
- Customization – Color (e.g., black or amber), shape, and film type
- Volume – Low volume orders incur higher unit costs
- Lead Time – Rush orders can add a 10–20% premium
2. Flexible PCB Coverlay Material Options and Their Costs
In 2025, the following are average material costs per square inch:
- Standard Polyimide + Adhesive (25μm + 25μm): $0.04–$0.08/in²
Ideal for most consumer electronics - High-Temperature Polyimide (35μm + 25μm): $0.08–$0.15/in²
Recommended for automotive, aerospace, and industrial controls - Adhesive-Free Coverlay: $0.12–$0.25/in²
Used in high-reliability or extreme temperature applications
These costs can fluctuate based on global polyimide film prices and adhesive supply chains.
3. Coverlay Processing and Labor Costs
Besides raw material costs, processing labor and tooling also contribute to the total price. For example:
- Laser Cut Openings: Add approximately $0.02–$0.05/in²
- Mechanical Punching: Less precise but more cost-effective, ~$0.01–$0.03/in²
- Manual Lamination for Small Batches: Add ~$15–$30 per batch
These numbers scale down significantly for high-volume production.
4. Cost Comparison: Flex PCB With and Without Coverlay
Let’s compare total costs for different production scenarios.
Example 1: Small Batch Prototype
- Qty: 10 pcs
- Size: 50mm x 50mm (approx. 2×2 in)
- 2-layer flex PCB with coverlay: ~$6.50 per board
- Without coverlay (solder mask only): ~$5.80 per board
→ Coverlay adds approx. $0.70 per unit (~12% increase)
Example 2: Mass Production
- Qty: 1000 pcs
- Size: 100mm x 100mm (approx. 4×4 in)
- 4-layer flex PCB with coverlay: ~$3.80 per board
- Without coverlay: ~$3.35 per board
→ Coverlay adds $0.45 per unit, but better long-term durability
5. How to Reduce Coverlay Costs Without Sacrificing Quality
To control coverlay-related expenses, consider these strategies:
- Use standard coverlay sizes and colors (e.g., amber, 25μm PI)
- Minimize the number of openings unless absolutely necessary
- Optimize your Gerber files for clean cutouts
- Consolidate production runs to reduce setup/tooling costs
Well-optimized designs can reduce coverlay costs by 10–20%.
6. Should You Choose Solder Mask Instead of Coverlay?
For cost-sensitive projects, you might consider replacing coverlay with a flexible solder mask:
| Option | Avg. Cost Impact | Pros | Cons |
| Coverlay | +$0.40–$0.80/pc | Excellent durability, insulation | More expensive, longer lead time |
| Flexible Solder Mask | +$0.10–$0.30/pc | Excellent durability, insulation | Less reliable in flexing zones |
For high-flex applications like wearables, coverlay is still the better long-term investment.
7. Flexible PCB Coverlay Cost with KingSunPCB
At KingSunPCB, we offer transparent pricing for flexible PCB manufacturing with coverlay:
- Prototype Orders (≤10 pcs): starting from $5.80/pc
- Small Batch Orders (50–100 pcs): from $3.50/pc
- Mass Production (500+ pcs): as low as $2.80/pc with coverlay
MOQ: 5 pcs | Lead Time: 7–10 working days (standard)
We also provide free DFM checks and suggestions to reduce your coverlay costs.
8. Conclusion
The cost of flexible PCB coverlay in 2025 ranges from $0.04 to $0.25 per square inch, depending on material, design complexity, and production volume. While coverlay does increase overall PCB cost, it offers unmatched reliability and protection, especially in demanding applications.
Ready to get a quote for your flexible PCB project with coverlay?
Contact KingSunPCB today for a fast, accurate quotation tailored to your design!