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.
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):
0.08/in² (consumer electronics)0.04–
High-Temperature Polyimide (35μm + 25μm):
0.15/in² (automotive, aerospace)0.08–
Adhesive-Free:
0.25/in² (high-reliability applications)0.12–
Prices vary with polyimide film and adhesive supply.
3. Processing and Labor Costs
Processing and tooling add to the cost:
Laser Cut:
0.05/in²0.02–
Mechanical Punching:
0.03/in²0.01–
Manual Lamination:
30 per small batch15–
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 (
Ready for a quote? Contact I-tech for a fast, tailored estimate!
