Rigid PCB Manufacturing

What a rigid PCB is — and where it fits

A rigid PCB is the workhorse of electronics: a solid, non-bendable board built from FR4 or other laminates with copper traces on one or both sides and between layers. Donlly builds rigid boards from 1 to 40 layers, and they remain the default choice for most consumer, industrial, automotive and medical devices because they are cheap to produce at scale and mechanically stable. When the board sits in a fixed enclosure, rigid is almost always the lowest-risk, lowest-cost answer.

Rigid PCB capabilities at Donlly

• Layer counts from 1 to 40, including multilayer and blind/buried via builds
• FR4 (standard, high-Tg and halogen-free), Rogers/PTFE for RF sections, aluminum for thermal dissipation
• Surface finishes: HASL, lead-free HASL, ENIG, immersion silver, OSP
• Minimum line/space down to 3/3 mil on selected lines, with impedance-controlled stacks
• Solder mask and legend in any color, including matte black and white

Materials and stack-ups

Most rigid boards start with FR4, but the laminate decides cost, signal loss and thermal behaviour. We help you pick the right material per signal speed and environment — FR4 for general digital, Rogers for RF and microwave, aluminum for LED and power, and polyimide hybrids where a flexible tail is required. A correct stack-up is cheaper than re-spinning a board that fails EMC or thermal limits.

Rigid vs flex vs rigid-flex — when to choose rigid

Choose rigid when the device does not bend, needs the lowest cost per unit, or must carry high layer counts and dense routing. If the product bends or saves space with a flexible section, see our flexible PCB and rigid-flex PCB pages. Rigid is also the better base when you need maximum layer count or the tightest impedance control.

Quality and standards

Every rigid board is built to IPC Class 2/3 with AOI, electrical test (flying probe or fixture) and full lot traceability. Panels are routed or V-scored to your outline, and we supply impedance and micro-section reports on request so your quality team can audit without friction.

From prototype to volume

Bare-board prototypes run in 24–72 hours; volume orders follow a qualified stack and the same test plan on every lot. Pair a rigid board with our PCBA assembly to receive a tested finished module from a single partner, or start with PCB prototyping before committing to volume.