Designing for Test: How to Simplify FFC Testing in New Product Development

When it comes to bringing a new electronic product to market, the design phase is where the foundation for success is built. Engineers spend countless hours optimizing form factor, performance, and manufacturability. But one area that’s often overlooked until late in the process is testability—specifically, how Flexible Printed Circuits (FPCs) and Flat Flex Cables (FFCs) will be tested during development and production.

At Flexible Test, we’ve seen first-hand how companies can lose valuable time and money by delaying test fixture considerations until prototypes are already in hand. The good news? A few design-for-test best practices can simplify the process and ensure your product is ready for fast, repeatable, and cost-effective testing.

Why Testability Matters in FFC Design

FFC and FPC cables are increasingly used in consumer electronics, automotive modules, medical devices, and industrial equipment because they save space, reduce weight, and enable compact designs. But these same advantages can make testing more complex.

Standard ZIF connectors used for validation often fail prematurely under repeated test cycles, leading to unreliable results and downtime. By designing with testability in mind, you can:

Reduce rework during validation and production ramp-up
Minimize costs associated with fragile test connectors
Accelerate time-to-market by streamlining quality assurance
Improve long-term reliability in the production line

Best Practices for Designing FFCs with Testing in Mind

1. Plan for Test Access Early

Don’t wait until prototypes are built to think about test connections. Providing dedicated test pads or accessible edge connections ensures your fixture can interface cleanly without redesigns later.

2. Consider Connector Pitch and Orientation

High-density FFCs can pose challenges for alignment and durability in test setups. Choosing pitches and orientations that align with proven test fixture standards makes the transition from design to testing much smoother.

3. Evaluate Fixture Durability Needs

Ask yourself: will the fixture be used just for R&D validation, or will it support high-cycle production testing? Production environments demand more rugged solutions, such as aluminum-backed FFC fixtures that withstand thousands of insertions without degradation.

4. Collaborate With Your Test Partner

Engaging with a test fixture partner early in the design cycle provides valuable feedback on connector selection, alignment strategies, and fixture options. Flexible Test has worked with OEMs across medical, automotive, and industrial sectors to recommend cost-effective fixture strategies tailored to their application.

How Flexible Test Simplifies the Process

At Flexible Test, our mission is to eliminate the bottlenecks caused by fragile connectors and short-lived test methods. Our FFC test fixtures are designed for repeatability, durability, and integration into both development labs and production environments.

By working with us early in your product development cycle, you can:

Avoid costly design changes late in the process
Ensure reliable, repeatable validation results
Build a clear path from prototype testing to scaled production testing

Conclusion

Designing with testability in mind isn’t just a best practice—it’s a competitive advantage. By considering how your FFCs will be tested during development, you can save time, reduce costs, and bring higher-quality products to market faster.

Flexible Test is here to help engineers simplify the testing process with robust, production-ready FFC fixtures. If you’re developing a new product and want to make testing simple, reliable, and scalable, reach out to our team today