Manufacturing Capabilities

FRALOCK combines over fifty years of experience in composite materials and manufacturing expertise to provide value-added solutions to some of the world’s most technically advanced OEM’s. We design and manufacture polymer, foil, ceramic, and adhesive-based products using thin, flexible materials and custom composites through a global supply chain.

We are an ISO 9001, AS9100, ISO 13485 certified, and FDA registered company dedicated to providing exceptional customer service, product realization, custom manufacturing solutions, and automated placement systems for the most demanding requirements. Fralock specializes in engineered solutions, providing components and subassemblies that are guaranteed to work in your application.

Our engineering team is able to quickly understand your performance needs and can often make suggestions that improve the reliability and performance of your products. In many instances, Fralock becomes a virtual extension of our customers’ engineering departments.
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Fralock utilizes a unique pioneered polyimide lamination process that eliminates the use of adhesives. Adhesiveless laminates provide high temperature resistance, dimensional stability, low outgassing, durability, and solvent resistance. Traditional polyimide laminates are notoriously unreliable at temperatures that exceed the Glass Transition (Tg) of the adhesives used in their construction.

Polyimide is closely matched to the CTE of copper, and can also be used to bond many other metals with bond strengths typically > 10 pli. If your application requires high temperature resistance, dimensional stability, low outgassing, durability, and solvent resistance, adhesiveless laminate technology is the solution.
We provide high-quality custom flex and rigid-flex circuit fabrication and electronic assembly solutions.
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  • Liquid Soldermask Thickness 25um (1mil)
  • Photo Imageable Coverlay Min 25um (1mil)
  • RoHS & Non RoHS PCB/Flex Circuit Manufacturing
  • Automated Optical Inspection (AOI)
  • Electrical Testing (Flying Probe, Function, and Hi-Pot)
  • Ability to Test for 10-15 Resistance Leakage
  • Trace / Space 37um (1.5 mil)
  • Micro / Vias Min 50u (2 mil)
  • Blind/Buried Vias (2mil)
  • Laser- Precision Drilling / Excising<50um (2mil)
  • Layer Count Capability 1-10+
  • Unsupported Traces / Cantilever Leads
  • Controlled Impedance Routing Capabilities
We provide the following assembly processes for your Flex and Rigid-Flex requirements:
  • 3 SMT Lines
  • Real Time X-ray
  • Automated Solder Paste Printer
  • In-Line Cleaning
  • Wave Solder (Leaded & Lead Free)
  • Inline Circuit Testing
  • 3D AOI Automated Optical Inspection
  • Laser Selective Soldering Machine With Preheat Oven
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We provide the following assembly processes for your Flex and Rigid-Flex requirements:
We offer protective coatings that are required in electronic circuit assemblies. Conformal Coating applied to electronic circuit assemblies protects against moisture, dust, chemicals, and temperature extremes.

  • Underfilling Encapsulation – protects in flip-chip packaging, reduces stress on solder bumps of chips, and protects against moisture, ionic contaminants, thermal vibration and shock.
  • Potting Materials – Protects the electronic assembly against vibration/shock, corrosion, and chemicals. Also provides electrical insulation, enhanced mechanical strength and heat dissipation.
Our plastic injection molding services include prototype, low and mid-volume production.
  • Pantone Color Matching
  • Textured Finishes
  • Resin Selection
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Our custom packaging solutions for medical and other industries include:
  • ESD Protection
  • Clamshell Design
  • Insert Trays Solutions
  • Inventory Management
  • Protection for Product Transportation
  • Medical Packaging
  • Custom Applications
Aerosol Jet systems print fine-feature electronic, structural and biological patterns such as 3D conformal sensors and antennas for medical, aerospace, defense, consumer electronics, wearables and the Internet of Things (IoT) – on to almost any substrate.

We provide:
  • Digital printing with no masks or stencils
  • Printed antennas, IoT, measurement applications
  • Printing on plastics, ceramics, and metallic substrates
No plating or etching is required. Feature sizes from 20+ microns.
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Fralock provides specialized imaging technology that allows greater precision at extremely large scales.
Extremely long Flat flex cables (hundreds of feet) can be produced.
  • Resolutions from 4,000 to 16,000 DPI
  • Large Scale; 48” width max, Length 20+ feet
  • Feature size to 12.5 micron
  • Film Masks;7 mil Mylar, Silver Halide emulsion
Imaging substrates include:
  • Plastics; Epoxy/Glass, Pyralux, Kapton, Polyimide, Ceramic, Teflon, Noryl, PEN, Cirlex, etc.
  • Thickness Range; .001” to .375” thick
  • Metal Cladding; Copper, Monel, Nickel, NiChrome, Stainless Steel; 1 micron to 5 mil thick
  • Bond; Adhesiveless, NiChrome sputter tie coat, or conventional adhesive bonded
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  • Plating, Lapping, Dicing and Brazing services
  • Heater Cooler Assemblies
  • Laser welding for high temperature lead attach
  • Pre-fired CNC machining tolerances +/- 1%
  • Post fired dicing to +/- .001”
  • Post Fired lapping/polishing to sub-micron flatness for parts up to 50mm square
  • Electroless Ni and Au plating
  • Metallizing and brazing of AlN heaters
  • Thin film coatings for ESD control or fine surface lines and spaces to 12um (.0005”)
  • Multi-zone Control systems with internal tungsten RTD, thermocouple or platinum RTD feedback capability
  • RoHS & REACH Compliant
Laser cutting service offers operators a highly accurate method of cutting complex shapes from a wide variety of materials. Our laser cutting services focus on extremely fine points and have enough energy to cut through thick materials with ease. Computer aided design (CAD) and computer numerical control (CNC) technology allows complex designs to be made by automated CO2 laser cutting machines quickly and with great accuracy. Laser cutting machines are integrated into a larger CAD/CAM (computer-aided-design, computer-aided-manufacturing) system that takes a design file and implements it on a work piece. These machines represent a stepping-stone in the continuing trend away from hands-on manufacturing, putting human workers in a more removed, creative design role.

CNC Milling: Fralock provides custom CNC cutting service that includes CNC milling, drilling, and routing. Our in house capabilities allow us to hold critical tolerances on flatness, true hole position and parallelism. Whether it’s a prototype or large quantities, we can insure no warping or bowing of your parts. We can offer quick turn-around and tight tolerances, with production quality.
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Die-Cutting: Fralock is an industry leader in specialty die cutting and converting of flexible materials. Fralock custom manufacturing provides design solutions for our customers’ critical parts for custom shapes, multi-layers, waste reduction, automated processing, and improved end product quality and longevity. Each of these processes offers a level of reliability, versatility, and performance that matches the needs of a particular industrial sector, type of business or application.
Die cutting capabilities include:
  • Rotary
  • Flatbed
  • Steel Rule – Short Run Flexibility
  • Class “A”
  • UV and CO2 Laser Cutting
  • Complex multi-layer island place die-cutting
  • CAD cutting, plotting, prototyping
  • Laser cutting
  • Flatbed or Progressive die-cutting
  • Steel rule dies
  • Multi-layer die-cutting
  • In-line optical registration die-cutting
  • Zoned adhesive or dead-end areas
  • Die-cuts for automation/pick-and-place dispensing
  • Liner swapping, split liners, extended tabs
  • (Ceramic Lamination from Oasis, also other capabilities like the stainless steel and glass lamination? Dielectric - temps up to 450 C)
  • Diamond Machining of Ceramics or Glass to Tight Tolerance
  • Ultra-Thin flexible zirconia substrates manufacturing
  • Ceramic Processing - Plating, Lapping, Dicing and Brazing
  • Thin Film Circuits – Ceramic substrates
  • Micro Cooling channels - Internal and External Channels in Aluminum Nitride
  • Cold Isostatic Pressing of Ceramic Powders to Near Net Shape
Whether you require and acrylic, rubber or silicone-based adhesive, Fralock is there for your adhesive coating services.

Fralock offers many adhesive coating methods to provide a solution designed specifically for your application.
Custom adhesives can be provided in tape, sheet, or precision die cut form.
Adhesive Coating Capabilities
  • Hot-melt adhesives
  • Thermoplastic adhesives
  • Dry edge capable
  • Slot or pattern coating”
  • Zone Coating
  • Adhesive Products
Transfer adhesive tapes
  • Single coated adhesive tapes
  • Double-coated (supported) adhesive tapes
  • Foamed adhesive tapes
  • Heat activated adhesive tapes
  • Custom widths, sheets, or precision die cut
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Fralock is one of the largest manufacturers providing precision slitting, converting and fabrication solutions, and we offer quick turnaround and rapid prototype manufacturing of film, tape, foils, etc., using the current CAD technology
Our precision slitting capabilities include the following:
  • Pull – Through
  • Re-Roll
  • Bologna Style
  • Micro Slitting from .015”
  • Custom widths
Various core/reel materials available
Medical device parts require high standards for cleanliness, and in some cases, sterility. The controlled environment of a clean room can help ensure that dust and other particulate matter do not contaminate the medical device manufacturing.
Fralock’s entire manufacturing floor is (at a minimum) Class 100,000. For manufacturing projects that require greater cleanliness and medical clean room processing and packaging, we offer Class 10,000, Class 1000 clean production rooms, high-filtration flow benches that have been certified at Class 1000 and a high-filtration bench that is operated with Class 10,000 procedures. We also offer portable cleanrooms that have tested at 10,000. Fralock is ISO13485 certified.