Coverlay FPC for Improved Electronic Solutions


Coverlay FPC is a flexible printed circuit that uses a plastic overlay to protect the surface of the circuit board. It provides insulation and protection from moisture, dust, and other environmental factors, making it suitable for various applications. This article will discuss the differences between Coverlay FPC and solder masks, the advantages of Artist 3D’s Coverlay FPC, and some of its disadvantages. It will also provide insight into the manufacturing process and give examples of applications where Artist 3D’s Coverlay FPC may be the best choice.

Brief Overview of Coverlay FPC

Coverlay FPC is a flexible printed circuit (FPC) that uses a plastic overlay to protect the surface of the circuit board. It is a thin and flexible sheet, usually the protective cover for electronic components. Engineers can cut it to fit over the components and then secure it with a heat bonder. Coverlay FPC protects from moisture, dust, and other environmental factors. It also provides insulation, covers the bare circuit areas and circuit traces, and prepares a surface finish for the pads.

Differences Between Soldermask and FPC Coverlay

The following are the variations between flexible PCB coverlay and solder mask:

  • A solder mask (also known as solder resist) is a liquid-based material, whereas a flexible PCB coverlay consists of glue and Kapton (a polyimide).
  • Solder mask dam sizes can go to a minimum of 4 mils, whereas coverlay dam sizes should go to 10 mils.
  • A coverlay can have a trace to mask opening as near as three mils, whereas engineers advise keeping a solder mask at a minimum distance of 4 mils.
  • Typically, Coverlay applies to the Flexible printed circuit’s flexible portions, whereas solder mask is applicable on the stiff or hard part of the PCB.
  • Coverlay cannot apply to components with pitch, unlike a solder mask.

Advantages of Coverlay FPC

flex board design

The following benefits of Coverlay FPC over traditional rigid PCBs make it the best option for many applications:

  1. Flexibility: Coverlay FPC can bend and curve to fit into nearly any area or layout because of its great flexibility. This feature makes it perfect for applications requiring close-quarters placement of components or restricted space.
  2. Robustness: Coverlay FPC is also incredibly robust, with a thick layer of plastic and copper foil that enables it to endure extremely high and low temperatures. It is, therefore, an excellent option for applications that demand long-term dependability.
  3. Price: Customers on a budget may find Coverlay FPC an appealing alternative because it is very inexpensive compared to rigid printed circuit board materials.
  4. Electrical Performance: The Coverlay FPC exhibit outstanding electrical performance, with low capacitance for high-speed communications and a common resistance channel for signals. It is, therefore, suitable for applications that need fast data transfer.
  5. The Coverlay FPC manufacturing process is rapid and straightforward, making it an excellent option for high-volume production runs.
  6. Versatility: Coverlay FPC is incredibly adaptable, making it an excellent option for many applications. It can be used in various products and applications, such as consumer electronics, medical devices, and automotive electronics.

Disadvantages of Coverlay FPC

The following are some of the drawbacks that come with the usage of Coverlay FPC:

  1. Heat Dissipation: Coverlay FPC is not as good at dissipating heat as other types of PCBs, as the material is not as thermally conductive. This aspect can lead to overheating components, which can cause the board to fail.
  2. Complexity: Coverlay FPC can be difficult to assemble and troubleshoot due to its complicated design. This aspect can be especially true for boards with multiple layers and complex routing.
  3. Space Limitations: Coverlay FPC is thicker than traditional PCBs, which can limit the amount of space available for components. This feature can be problematic in applications where size and weight are important factors.
  4. Limited Lifespan: Coverlay FPC has a shorter lifespan than traditional printed circuit boards due to their fragile nature. This aspect can be an issue in applications where long-term reliability is necessary, such as medical or aerospace applications.
  5. Fragility: Coverlay FPC is more fragile than traditional printed circuit boards due to the nature of the flexible substrate. This fragility can be an issue when exposed to mechanical and environmental stresses, as it can cause the circuit to fail.

Applications of Coverlay FPC

We can use Coverlay FPC in many applications, including:

  1. Automobile Electronics: Coverlay FPC protects automotive electronics from chemicals, moisture, and dust. The PCB’s lifespan may increase and corrosion prevented. Additionally, it offers electrical insulation and aids in maintaining a solid connection between the circuit boards.
  2. Medical Devices: To add further defense against contaminants, moisture, and chemicals, there is use of Coverlay FPC in medical devices. It also aids in stopping the development of bacteria and mold. This action makes the use of medical equipment safer and more effective.
  3. Telecom Equipment: Coverlay FPC shields it from environmental elements like moisture and dust. Preventing the transmission of extraneous signals helps ensure the data transfer’s correctness.
  4. Consumer Electronics: We use Coverlay FPC in consumer electronics to shield equipment from environmental contaminants, including moisture and dust. It helps protect the delicate parts of consumer devices like computers, tablets, and cell phones from deterioration
  5. Industrial Electronics: To shield industrial electronics from dirt, moisture, and other external factors, we use coverlay FPC. It ensures that the electronic parts are secure, safe, and functional in challenging industrial settings.

Coverlay FPC Market trends

Over the past few years, the coverlay FPC market has grown steadily. This growth is primarily because of the rise in demand for consumer devices like laptops, tablets, and smartphones. In addition, the necessity for high-performance circuit boards and the growing emphasis on product downsizing have fueled the need for coverlay FPC. The market for coverlay FPC has expanded due to the rising demand for high-quality goods with upgraded features. This market has also been fueled by manufacturers’ raising awareness of the need to boost the quality of their products while cutting costs.

Additionally, the popularity of green electronics has raised the need for coverlay FPC. These goods are favored over alternatives since they consume very little energy and are simple to recycle or dispose of. by the expanding use of coverlay FPC in automotive and medical applications has fueled the expansion of this industry.


Coverlay FPC is a great way to reduce cost and complexity for various electronics projects. In addition, it can provide a great way to add features and create a more efficient design. Overall, Artist 3D’s Coverlay FPC is an excellent choice for applications that require a high degree of flexibility and durability. In addition, it is relatively inexpensive, lightweight, and highly versatile, making it an ideal choice for various applications.

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