Flexible Circuit Technologies Delivers Advanced Catheter Flexible Circuits for Enhanced Medical Performance

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Flexible Circuit Technologies is a leading provider of specialty interconnect solutions that support complex and mission-critical applications. Their extensive portfolio includes flexible circuits, rigid-flex assemblies, flexible heaters, catheter circuit assemblies, membrane switches, plastic molding, sterilization solutions, and full-spectrum EMS (Electronics Manufacturing Services) ranging from PCB assembly (PCBA) to complete box builds.

Among their most sophisticated offerings of Flexible Circuit Technologies is a dedicated line of catheter flexible circuits, designed specifically to elevate the performance, reliability, and integration capability of today’s advanced medical catheters. These catheter-related solutions provide minimally invasive procedures while addressing a broad range of applications. These applications include catheters for ablation, electrophysiology, mapping and diagnostic, angioplasty, stent deployment, and more.

These catheter flexible circuits solutions range from single-layer to six-layer constructions, enabling integration of multiple functionalities such as signal transmission, sensing, power delivery, and control, all within the slender profile of a catheter shaft. The minimum board thickness for single-sided circuits is 0.065 mm, while double-sided boards start at 0.125 mm. Multilayer configurations are tailored based on customer specifications to balance functionality and device diameter.

Precision manufacturing capabilities allow for ultra-fine feature sizes, with conductor widths and spacing down to 0.05 mm on single and double-sided boards, and 0.075 mm for multilayer builds. This high-density interconnect (HDI) capability is crucial for embedding sophisticated electronics into catheters used in neurovascular, electrophysiology, and cardiovascular procedures. Additionally, laser-drilled micro holes with diameters as small as 0.05 mm and mechanically drilled PTHs as small as 0.10 mm enable robust vertical interconnections while conserving space.

Catheter circuits from Flexible Circuit Technologies also feature excellent material and reinforcement options, essential for ensuring mechanical durability during insertion and manipulation within the human body. Shielding films of 16 µm and 20 µm provide effective EMI protection, while optional FR4, polyimide (PI), or metallic stiffeners—ranging in thickness from 0.075 mm to 0.5 mm—offer reinforcement without compromising flexibility. These elements make the circuits ideally suited for dynamic medical environments that demand both mechanical compliance and operational stability.

To meet the stringent cleanliness and biocompatibility standards of the medical device industry, Flexible Circuit Technologies ensures tight control over manufacturing processes. The boards support multiple surface finish options, including ENIG (Electroless Nickel/Immersion Gold), electroplated hard gold, and soft gold, all of which offer excellent solderability, corrosion resistance, and longevity. The maximum panel size of 250 mm by 1500 mm supports high-volume catheter builds, allowing for efficient manufacturing of long-format circuit designs used in imaging and ablation catheters.

The catheter flexible circuits also include precise impedance control, with differential impedance maintained at 100 ohms ±10%, ensuring signal integrity for high-speed data acquisition and wireless telemetry. Alignment tolerances between layers are held within ±0.05 mm, which is essential for maintaining interlayer continuity and functionality in compact multilayer builds.

In terms of final fabrication, laser trimming is used for outlines narrower than 1 mm to ensure smooth, burr-free edges, while mechanical tooling is employed for wider outlines. Ultimately, the catheter flexible circuits delivered by Flexible Circuit Technologies represent a blend of advanced materials engineering, microelectronics, and biomedical design. These solutions are specifically crafted to help medical device manufacturers push the boundaries of what’s possible in catheter-based diagnostics and therapy, providing ultra-compact, reliable, and high-performance interconnects for the most demanding clinical environments.

Click here to learn more about these catheter flexible circuit solutions.