Flexible PCBs are essential in modern electronics—from wearable devices to aerospace systems. One of the most critical design parameters in flex PCB production is thickness, which directly impacts flexibility, cost, reliability, and the manufacturing process. In this guide, we’ll explore the top 6 common thickness options for flexible PCBs, paired with actual pricing to help you make informed sourcing decisions in 2025.
1. Factors That Influence Flexible PCB Thickness Selection
When designing a flexible PCB, thickness is not just a number—it plays a critical role in performance, durability, and cost. Here are the main factors that influence your thickness choice:
Application Environment
Different applications demand different thickness levels. For instance:
- Medical devices often require ultra-thin and lightweight designs.
- Automotive or industrial PCBs may require thicker layers to withstand vibration, heat, and mechanical stress.
- Wearables need a balance of flexibility and strength.
Bend Radius Requirements
The bend radius determines how tightly the flex PCB can be folded without damage. As a general rule, thinner boards offer a smaller minimum bend radius, making them more suitable for compact or dynamic-flex applications. Thicker boards, while more durable, are harder to bend and better suited for static-flex setups.
Circuit Complexity and Layer Count
More complex circuits may require multiple layers of copper and dielectric materials, increasing the total thickness. Multilayer flexible PCBs (e.g., 4 or 6 layers) usually range between 0.2mm to 0.5mm, depending on the stack-up design and insulation requirements.
Assembly and Handling Constraints
If the board will be assembled using automated equipment, slightly thicker options (such as 0.2mm to 0.3mm) provide more structural stability and ease of handling during pick-and-place processes.
2. Top 6 Flexible PCB Thickness Options in 2025
Flexible PCB materials typically include polyimide (PI) base material, adhesive layers, and copper foil. Thickness includes both the dielectric and copper layers. Here’s a deeper look at the top 6 thickness options and their real-world uses:
2.1 0.05mm (50μm) – Ultra-Thin Flexible PCBs
Ideal for extreme miniaturization, such as micro-sensors or compact cameras. These boards offer exceptional flexibility but require special handling during both manufacturing and assembly due to their fragility.
- Copper: 1/3 oz or thinner
- Use case: Medical implants, micro-electronics, bend-to-install components
- Caution: Limited mechanical strength
2.2 0.1mm (100μm) – For Compact and Wearable Devices
A widely used thickness for products that require light weight and moderate durability. Common in wearables, fitness bands, and mobile accessories.
- Good compromise between flexibility and strength
- Suitable for dynamic flex applications
2.3 0.13mm – Cost-Effective General-Purpose Option
This is one of the most popular standard thicknesses for general applications. It offers:
- Decent flexibility
- Easy handling
- Competitive pricing
Recommended for consumer electronics, flexible interconnects, or simple LED modules.
2.4 0.2mm – Balanced Thickness for Consumer Electronics
Provides mechanical strength and compatibility with automated assembly lines, while still maintaining moderate flexibility. Often used in:
- Tablets, smartphones
- Foldable displays
- Control panels
2.5 0.3mm – Industrial & Automotive Applications
For use in environments with higher stress or frequent vibration. This thickness allows better support for stiffeners and multiple signal layers.
- Better durability under thermal cycles
- Common in automotive dashboards, LED lighting modules
2.6 0.5mm – Heavy-Duty & Stiffener-Ready Design
This is the thickest commonly used flexible PCB option, often integrated with stiffeners or hybrid rigid-flex structures. It supports:
- Large copper areas
- Better mechanical load distribution
- Applications like aerospace controls, radar modules, and military devices
3. Real-World Flexible PCB Prices by Thickness
Below are estimated prices from KingSunPCB based on standard FR4 + polyimide construction, 1-2 layers, and 100 pcs batch:
| Thickness | Price per 100pcs (50x50mm) | Notes |
| 0.05mm | $180 – $220 | Ultra-thin handling surcharge applies |
| 0.1mm | $140 – $180 | Popular for wearables |
| 0.13mm | $120 – $150 | Entry-level and general use |
| 0.2mm | $130 – $160 | Balanced price-performance |
| 0.3mm | $150 – $190 | More copper/PI layers included |
| 0.5mm | $170 – $210 | Stiffener support recommended |
Note: Prices vary based on quantity, surface finish (ENIG, OSP), and additional requirements like impedance control or stiffener integration.
4. How to Choose the Right Thickness for Your Project
Ask yourself the following:
- Do I need tight bending? → Go thinner (≤0.13mm)
- Is durability more important than flexibility? → Choose ≥0.2mm
- Do I have space constraints? → Thinner PCBs save vertical space
- Will it be auto-assembled? → 0.2–0.3mm offers better handling
A good rule of thumb is: the thinner, the more flexible—but also the more fragile and expensive to handle.
5. Cost-Saving Tips When Ordering Flexible PCBs
Managing costs while maintaining quality is a priority for most engineers and procurement teams. Here are several proven strategies to reduce costs when ordering flexible PCBs:
Optimize Panel Utilization
Combining multiple small designs into a single panel can drastically reduce tooling, setup, and material waste. Panelization improves efficiency and lowers the unit price per board.
Simplify the Stack-Up
Avoid adding unnecessary copper layers or using exotic materials unless required. For instance, if a 2-layer board is enough for your signal routing and grounding needs, don’t use a 4-layer board just to be safe.
Eliminate Over-Specification
Over-specifying the copper weight, surface finish, or tolerances can lead to unnecessary cost increases. Standard specs such as 1 oz copper, PI substrate, and ENIG or OSP surface finish are often sufficient for most use cases.
Order in Batch, Not Per Prototype
Even a small increase in quantity (e.g., from 10 to 100 pcs) often results in a significant cost reduction per unit due to economies of scale in manufacturing.
Work With an Experienced Manufacturer
An experienced flex PCB supplier like KingSunPCB can offer free DFM checks, spot potential design issues early, and recommend cost-effective alternatives—saving you from future revisions and hidden costs.
6. Why Choose KingSunPCB for Flexible PCB Manufacturing
At KingSunPCB, we specialize in flexible and rigid-flex PCB production for global clients. Here’s what makes us stand out:
- Custom thickness options from 0.05mm to 0.5mm+
- Instant online quoting system
- Strong engineering support for DFM and DFX
- Global shipping with fast turnaround (as quick as 48 hours)
- Certifications: ISO9001, UL, RoHS, IATF16949
7. Conclusion
Understanding how flexible PCB thickness impacts pricing and performance is essential for any engineer or buyer in 2025. Whether you’re designing next-gen wearables or industrial modules, choosing the right thickness can save costs, improve performance, and reduce turnaround times.
Get a customized quote now or download our full thickness & pricing chart to compare your options.