Manufacturing of Flexible Printed Circuit Boards for MRI Systems

Abstract

This paper focuses on the advanced manufacturing of a flexible printed circuit board (PCB) specifically designed for use in magnetic resonance imaging (MRI) machines. Flexible PCBs offer unique advantages over traditional rigid counterparts, particularly in environments requiring space efficiency and dynamic applications. The flexibility of these PCBs allows for their integration into compact and curved spaces within the MRI system, optimizing space utilization and enabling superior design freedom in assembly. This paper explores the complete lifecycle of flexible PCBs (FPCs), focusing on material selection and the creation of multi-layered, highly conductive pathways for efficient signal transmission in high-resolution imaging. Key production stages include etching, drilling, plating, and lamination, with an emphasis on how these processes affect performance, reliability, and cost-effectiveness. Advanced manufacturing techniques, such as pneumatic presses for die cutting, CNC drilling for precision routing, and Automated Optical Inspection (AOI) for error detection, are employed in this work to ensure thermal and mechanical resilience. The resulting flexible PCB offers improved adaptability and reliability, enhancing performance in sophisticated medical imaging technology and contributing to more accurate diagnostics and patient care.

Introduction

Flexible Printed Circuits (FPCs) are essential components in MRI machines, which operate in challenging environments with strong magnetic and radio-frequency fields. FPCs must ensure high electromagnetic compatibility, signal integrity, and durability while fitting into compact, curved spaces. Their flexibility allows them to withstand bending and vibrations better than rigid PCBs, leading to more efficient, lightweight, and reliable MRI system designs.

FPCs improve MRI performance by reducing electromagnetic interference and eliminating bulky connectors, enhancing imaging accuracy and patient care. Advanced materials like polyimide, copper foils, and protective coatings are used in their manufacture to meet thermal, mechanical, and electrical demands. Manufacturing involves precise cutting, stacking, CNC drilling, routing, and chemical processes such as electroless plating to ensure reliable electrical connectivity, especially in multilayer designs.

Research using Finite Element Analysis and fatigue life assessment highlights the superior durability of flexible PCBs, especially in dynamic or damp environments, advocating for their wider adoption in medical and high-performance electronics. Overall, the design and production of flexible PCBs tailored for MRI machines represent a significant innovation, optimizing device performance and advancing healthcare diagnostics.

Conclusion

The project on advanced manufacturing techniques for Flexible Printed Circuit Boards (FPCBs) demonstrates significant progress in meeting the unique demands of Magnetic Resonance Imaging (MRI) systems. By optimizing materials, processes, and integrating innovative technologies, it achieved enhanced flexibility, durability, and electromagnetic compatibility, enabling compact and reliable MRI systems for improved diagnostics. Advanced processes such as CNC drilling, automated inspection, and precision chemical treatments ensure high performance under stress, showcasing potential applications in aerospace and defence. This interdisciplinary effort highlights the role of emerging technologies in advancing medical imaging and setting benchmarks for high-performance, space-efficient electronics. 3D printing may represent the future of PCB manufacturing, offering customization, intricate designs, and rapid prototyping, driven by innovations in flexible, conductive, and biocompatible materials for applications like wearables and medical devices. While challenges such as material limitations, scalability, and resolution persist, hybrid approaches and advanced materials hold potential for addressing these issues in specialized applications.

References

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Copyright

Copyright © 2025 K Aksharaakruthi, M Puneeth, B Sukesh Kumar, V Megha Syam Gopal, T Niranjan. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.