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A common rigid-flex PCB structure consists of one or more flexible PCBs sandwiched between two sets of rigid cover plates. The cover plate area remains wire-free and is eventually removed.

Subtractive fabrication is the most commonly used method in FPCB fabrication. It can produce circuits of a certain thickness, and terminals can be made from almost all known metals. It allows for localized repairs or rework without requiring special equipment.

The direct terminal exposure process used in single-sided flexible board manufacturing can also be extended to double-sided flexible board manufacturing, where terminals are directly exposed on the pads, allowing for assembly on both sides.

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Machining is only suitable for a limited number of windowing applications because windowing is a time-consuming, costly, and demanding process with a significant risk of pad damage.

Single-sided flexible boards do not require interlayer connectivity, therefore plating vias are unnecessary. Double-sided, multilayer, or rigid-flex boards require metallization after drilling, necessitating additional steps such as plasma or chemical descaling.

The correct method for drilling flexible sheets involves using a high feed rate to ensure the drill bit moves steadily into the fresh, cold material, and using good cover plates and backing plates.

Rigid-flex board precautions: the shape of the flexible and rigid boards; special tool slots, windows and bevels; single-sided or double-sided flexible areas, assembled or unassembled components; material selection; specifications.