Overcoming Design Limits with a Tailored Flex Circuit Assembly
Challenge
Epec was approached by a new customer that came to us with a specific need: to replace a traditional cable assemblies in their product with something more rugged, efficient, and easier to assemble. Their legacy solution relied on multiple individual cable connections, which were not only cumbersome to assemble but also lacked the structural integrity required for their application.
Complicating the matter, the length of the flex circuit they required exceeded what many other suppliers could support. They had already been turned away by some vendors who stated that their required dimensions were beyond feasible manufacturing limits.
Adding to the challenge, their internal team had limited experience with complex flex circuit assemblies of this size and scope. They weren’t just looking for a supplier; they needed a partner who could help guide the process from concept through to manufacturing.
The project’s complexity required close collaboration, and they were also concerned about the risk that multiple-piece solutions would increase points of failure. Reducing hand assembly time was a major objective as well, as their original design involved several hours of labor per unit, resulting in higher costs and inconsistencies in production.
Solution
The engagement began when they submitted a contact form on Epec’s website. They were quickly routed to a member of our sales team, who conducted an initial discovery call to assess the viability of the project. During that conversation, it became clear that this wasn’t a simple flex circuit design; it would require a complete flex assembly solution tailored to their mechanical and electrical requirements. The sales team brought in our engineering staff early to assist in defining the scope and reviewing technical feasibility.
We started by gathering as much detail as possible on their existing assembly. This included documentation, photos, and firsthand explanations of how the original cable assemblies were installed, used, and maintained. By understanding the fit and function in detail, we were able to identify a practical path forward.
Our engineering team proposed a single-piece flex circuit design, long enough to meet their needs, and terminated with a connector on one end. This allowed the customer to eliminate multiple interconnect points, improving reliability and simplifying the overall system design.
Beyond just the flexible circuit itself, Epec provided a complete flex assembly. This meant integrating the circuit with specific mounting and interface features tailored to their equipment. We held multiple rounds of technical discussions, where we collaborated with their team to validate mechanical tolerances, connector specifications, and mounting constraints. Every element of the design was reviewed not just for function but also for manufacturability, ensuring that what was designed could be manufactured at scale.
Importantly, Epec offered guidance on material selection to meet environmental and performance requirements, such as choosing the right polyimide layer stack-up for flexibility and durability. Our manufacturing capabilities allowed us to accommodate the unusually long flex design without resorting to joining multiple pieces, which many other vendors were trying to suggest as a substitution. By keeping the design continuous, we were able to minimize signal loss, reduce potential failure points, and streamline the customer’s installation process.
Result
The first lot of production parts were delivered successfully and met all performance and quality expectations. The streamlined, single-piece flex assembly reduced the estimated assembly time from several hours per unit to under 30 minutes, and in some cases even faster. This improvement alone had a measurable impact on their throughput and labor efficiency.
But the result didn’t end with one part number. The success of the initial project led them to expand their engagement with Epec. What started as a single custom flex assembly has now grown into four distinct part numbers, each tailored for slightly different use cases and configurations within their product family. Each variation benefits from the design and manufacturing foundations laid during the original development process.
In addition to improving internal efficiencies, they also gained confidence in their ability to scale and adapt their product architecture. Epec's support gave them a trusted resource they could turn to for complex interconnect and assembly solutions, something they hadn’t found with other vendors. The collaborative approach helped ensure that the final product not only met technical requirements but also supported long-term production goals.
Had they continued down their original path, they likely would have spent significantly more time and resources on manual assembly, experienced more quality issues due to handling multiple cables, and potentially delayed their time to market. Instead, Epec’s solution allowed them to simplify their design, reduce risk, and position themselves for future growth with a scalable interconnect platform.
This project underscores the value of engaging with a supplier who understands not just manufacturing but also the complete product lifecycle, from initial concept to design validation, to repeatable production. With Epec, this customer found more than just a manufacturer; they found a long-term partner committed to solving complex design challenges with practical, production-ready solutions.
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