Flex PCB Coverlay Price

Flexible PCBs are popular in modern electronics because of their lightweight, space-saving, and bendable features. A crucial part of flex PCB design is the coverlay. It's a protective insulating layer that shields the copper circuitry from moisture, chemicals, and mechanical damage.

In 2025, with rising raw material and labor costs, the flexible PCB coverlay cost  has become a more significant concern. This guide explains the actual cost of flexible PCB coverlay and the factors that affect its price.
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1. Factors Influencing Flexible PCB Coverlay Price

Several elements determine the coverlay price in flexible PCB manufacturing:

  • Material:Polyimide film type, adhesive, and temperature resistance

  • Thickness: Ranging from 12.5μm to 50μm

  • Design: Complexity, cutouts, size, and tolerance

  • Customization: Color, shape, and film type

  • Volume: Low volume drives up unit costs

  • Lead Time: Rush orders incur a 10–20% premium

2. Material Options and Costs

In 2025, average costs per square inch:

  • Standard Polyimide + Adhesive (25μm + 25μm):

    0.04–
    0.08/in² (consumer electronics)

  • High-Temperature Polyimide (35μm + 25μm):

    0.08–
    0.15/in² (automotive, aerospace)

  • Adhesive-Free:

    0.12–
    0.25/in² (high-reliability applications)

Prices vary with polyimide film and adhesive supply.

3. Processing and Labor Costs

Processing and tooling add to the cost:

  • Laser Cut:

    0.02–
    0.05/in²

  • Mechanical Punching:

    0.01–
    0.03/in²

  • Manual Lamination:

    15–
    30 per small batch

Costs drop for high-volume production.

4. Cost Comparison: With vs Without Coverlay

  • Small Batch (10 pcs, 2×2 in): Coverlay adds $0.70/unit (12% increase)

  • Mass Production (1000 pcs, 4×4 in): Coverlay adds $0.45/unit, enhancing durability

5. Cost Reduction Strategies

To cut costs without sacrificing quality:

  • Use standard sizes and colors

  • Minimize unnecessary openings

  • Optimize Gerber files

  • Consolidate production runs

Well-optimized designs can cut costs by 10–20%.

6. Coverlay vs Solder Mask

For budget projects, flexible solder mask may replace coverlay.

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 the ideal long - term choice.

I-tech Flexible PCB Coverlay Pricing

We offer transparent pricing:

  • Prototype (≤10 pcs): from $5.80/pc

  • Small batch (50–100 pcs): from $3.50/pc

  • Mass production (500+ pcs): as low as $2.80/pc

With a 5 - piece MOQ and 7–10 - day lead time, we provide free DFM checks to optimize costs.

Summary

In 2025, coverlay costs  (

0.04–
0.25/in²) vary by material and volume. While it increases PCB cost, coverlay delivers top - notch reliability.

Ready for a quote? Contact I-tech  for a fast, tailored estimate!