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by pjc50 3982 days ago
I suspect flexing the PCB caused the usual problems of hairline cracks in solder joints, resulting in intermittent faults.
1 comments

If that's true, I wonder if something like a paper circuit would work? e.g., http://www.instructables.com/id/Paperduino-20-with-Circuit-S...
Flexible substrates are not a problem - the industrial solution is polyimide (Kapton) or just really thin FR4. The problem is inflexible components. As soon as you bend a curved surface attached to a small flat rectangle (IC), it pulls at the joins.

You might get better results with bare die+wirebonding, then encapsulating with slightly flexible epoxy. That would allow the bondwires to flex and take up the bending. Doesn't help with the discrete components or the battery.