My Account
We compare quotes from leading insurers
INSURANCE BUILT FOR FLEXIBLE PCB RISKS
Why Flexible & Flex-Rigid PCB Manufacturing Needs Specialist Insurance
Flexible and flex-rigid printed circuit boards sit at the “high consequence” end of electronics manufacturing. The product is typically lightweight, compact and highly engineered — and it’s often used in environments where failure is expensive: medical devices, aerospace, defence, industrial control, automotive, instrumentation, and compact consumer electronics. That means one small manufacturing deviation can create large downstream costs.
Compared to rigid PCB production, flexible circuitry introduces additional complexity: polyimide and other films, adhesive systems, coverlays, stiffeners, controlled bending radius requirements, dynamic flex performance, and more sensitive handling and storage. Quality losses can come from tiny issues: contamination, misregistration, copper cracking, delamination, via integrity, impedance variation, or moisture/chemical exposure.
The right insurance programme does two things: (1) protects the factory itself (property, stock, plant and machinery) and (2) protects the balance sheet when customers allege defects, failures, or financial loss. Insure24 structures cover for PCB manufacturers so it reflects how the risk really behaves.
What Insurance Does a Flexible PCB Manufacturer Typically Need?
Most flexible PCB manufacturers need a combined programme rather than a single policy. Your risks span property damage, operational interruption, product liability, professional/design exposures, and sometimes environmental and cyber risks. The correct structure depends on what you manufacture, what sectors you supply, where products go, and whether you also do assembly, cable harnessing, testing, or on-site support.
Core Covers
- Property insurance – buildings (if owned), tenants’ improvements, contents, plant and machinery.
- Stock / materials – copper-clad laminates, films, coverlays, adhesives, chemicals and finished boards.
- Business interruption – protects cashflow during downtime after insured events (fire, flood, etc.).
- Employers’ liability – usually required in the UK if you employ staff.
- Public & product liability – third-party injury/property damage from activities and products.
Specialist / Often Needed
- Professional indemnity – design/specification, advice, performance representations, “fitness for purpose” disputes.
- Product recall / rectification – practical cost of removing/replacing defective products (not usually covered by product liability).
- Equipment breakdown – sudden breakdown of key machinery (where arranged).
- Environmental liability – clean-up and pollution claims (use of chemicals/waste streams can create exposure).
- Cyber & data – ransomware/OT disruption, data liability and incident response costs.
The most common “gap” for PCB manufacturers is assuming product liability covers everything. It usually does not cover the cost of replacing your own products, recall campaigns, or pure financial loss from downtime unless linked to injury/property damage. Where you supply OEMs, you also need to align policy limits, territories and contract clauses to what your customers require.
Key Risks in Flexible & Flex-Rigid PCB Manufacturing
Flexible PCB risks are not just “the same as rigid boards.” Your process chain can involve lamination, drilling/laser processing, imaging, etching, plating, coverlay application, stiffener bonding, surface finish, routing, testing and sometimes assembly or functional verification. Each stage introduces failure modes that can impact reliability, bend performance and electrical integrity.
The insurance impact is driven by two factors: (1) the cost of scrap/rework and (2) the downstream consequence if boards fail in customer systems. The more embedded the product (and the higher the end-use sector), the more critical it is to have robust liability and recall/rectification planning.
Manufacturing / Process Failure Modes
- Delamination, blistering, adhesive failure or poor bonding between layers
- Copper cracking at bend points, fatigue issues and dynamic flex performance failures
- Misregistration, dimensional instability and layer alignment issues
- Via integrity problems, microvia defects or plating voids
- Contamination leading to leakage currents, corrosion or intermittent faults
- Coverlay defects, exposure, cut-back errors or poor adhesion
- Impedance control failures for high-speed applications
- Incorrect stiffener placement/adhesion affecting assembly or connector interfaces
Commercial / Contract Risk Drivers
- OEM terms requiring you to pay costs even without “negligence” being proven
- “Fitness for purpose” and broad warranty clauses in supply agreements
- Downstream integration into high-value devices and assemblies
- Territory risk: export and re-sale into USA/Canada or other jurisdictions
- Urgent field action costs if defects are discovered after shipment
- Customer audits and re-qualification requirements after an incident
- Reputational risk and loss of key customer status
- Supply chain disruption for films/adhesives/specialist materials
Insurers assess both your process controls and your customer profile. A flex circuit used in a consumer gadget has a different loss severity profile to one used in medical monitoring equipment. We help you present the risk clearly so you’re not priced on worst-case assumptions.
Property, Stock & Materials Cover for Flexible PCB Facilities
Flexible PCB production often involves higher sensitivity materials and more stringent storage and handling requirements. Polyimide films, adhesive systems, coverlays and specialist laminates can be high value and can become unusable if exposed to moisture, contamination, incorrect temperatures or chemical cross-contamination. Some sites also store chemicals used for processing, cleaning, plating and finishing.
A well-structured property policy should reflect the true nature of your assets: clean areas, controlled storage, specialist equipment, and high-value WIP. It should also be set up with realistic declared values and a plan for how stock fluctuates through the year.
Items That Must Be Declared Correctly
- Raw materials (films, laminates, copper foils, coverlays, stiffeners)
- Work in progress (part-processed panels and assemblies)
- Finished goods (boards ready for shipment and packaged stock)
- Tooling, jigs, fixtures and specialist test equipment
- ESD/clean area infrastructure and tenant improvements
- Customer-owned goods (if held at your premises)
- High-value consumables and specialist chemicals (where relevant)
Common Property Gaps to Avoid
- Underinsurance – values not updated, leading to average clause reduction at claim time
- Wrong settlement basis – indemnity vs reinstatement confusion on plant/equipment
- Stock peaks ignored – maximum seasonal material holdings not covered
- Water damage assumptions – escape of water/flood deductibles and sub-limits overlooked
- Security conditions – theft cover depends on alarm/CCTV compliance
- Specialist items not listed – test rigs/tooling omitted from declared values
The best way to improve terms is to provide underwriters with a simple, accurate summary of your site: building construction, fire protection, housekeeping, security, material storage methods, and your quality controls. Insurance is easier (and often cheaper) when underwriters don’t have to guess.
Product Liability vs Recall/Rectification vs Professional Indemnity (Why You May Need All Three)
Flexible PCB disputes often involve more than “a board broke.” Customers may allege a manufacturing defect, a design/specification issue, or claim for financial loss (downtime, rework, penalties). Different policies respond to different triggers. Understanding the boundaries helps you avoid uninsured losses and improves how you negotiate contracts.
Product Liability (Typical Scope)
Product liability is designed for claims involving third-party injury or third-party property damage caused by your products after they leave your control.
- Defective boards cause damage to customer equipment or systems
- Safety incidents involving electrical or thermal hazards linked to a failure
- Legal defence costs for covered product claims
- Contract-driven limits and territories can apply
What It Usually Does NOT Cover
- The cost to replace your own defective products (your “own goods”)
- Recall/field action programmes to remove/replace boards
- Pure financial loss (downtime/penalties) without injury/property damage
- Design/advice disputes framed as professional negligence
This is why many manufacturers add recall/rectification and professional indemnity where exposures justify it.
Recall / Rectification (Field Failure Costs)
- Tracing affected batches, customer communications and logistics
- Replacement manufacture, shipping, returns and disposal
- On-site engineer time where boards are embedded and require field support
- Testing, verification and controlled rework costs (wording dependent)
This cover is especially relevant if your boards are widely distributed, embedded into larger systems, or supplied into higher reliability sectors.
Professional Indemnity (Design / Spec / Advice)
- Claims that your design advice, stack-up guidance or specification support was negligent
- Performance representations (impedance, bend radius, dynamic flex life) leading to financial loss disputes
- Errors in documentation, drawings, data packs or manufacturing instructions
- Certain “fitness for purpose” style disputes (wording dependent)
If you provide engineering support, DFM input, or spec sign-off, PI is often a key part of the overall programme.
Business Interruption, Long Lead Times & Supply Chain Risk
For PCB manufacturers, the biggest losses after a major incident are often not the physical damage — they’re the knock-on effects: missed deliveries, urgent outsourcing, lost key customers, and the cashflow impact of downtime. Business interruption (BI) is designed to protect profit and cover increased cost of working while you recover.
Flexible PCB manufacturing can have longer recovery timelines because restarting requires: replacement of specialist equipment, re-qualification of processes, reinstatement of controlled areas, and re-ordering of sensitive materials with lead times. If you supply high-reliability sectors, customers may require audits before resuming orders.
BI: The Big Decisions
- Indemnity period – 12, 18, 24 or 36 months depending on realistic recovery time
- Gross profit sum insured – must reflect current turnover and growth projections
- Increased cost of working – outsourcing, overtime, temp premises, expedited freight
- Claims preparation – costs for accountants/evidence building
- Utilities / denial of access – cover where loss is caused by nearby events or power issues (wording dependent)
Supply Chain: What to Map
- Single-source materials (films, adhesives, specialist laminates)
- Critical subcontractors (plating, finishing, testing, assembly partners)
- Key logistics nodes (warehousing and shipping routes)
- Alternative suppliers and qualification requirements
- Contingent BI options for key suppliers/customers (availability varies)
Insurance works best when it supports a real continuity plan: who you can outsource to, what you can prioritise, and how you maintain customer confidence.
What Underwriters Typically Ask for (Flexible PCB Submission Checklist)
PCB manufacturing is underwritten on process discipline, customer profile and risk controls. The information below helps underwriters price accurately — which can improve terms and reduce delays. Even a one-page summary with the right details can transform the quotation experience.
Business & Products
- Products: flexible, flex-rigid, rigid-flex, assembly, testing, prototyping vs volume
- End-use sectors (medical, aerospace, defence, automotive, industrial, consumer)
- Turnover split by product type and geography
- Largest customers and contract requirements (limits/territory)
- Export and resale routes (especially USA/Canada exposure)
- Any safety-critical applications or certification requirements
Operations & Controls
- Quality systems, traceability, testing regimes and inspection points
- Change control, CAPA, supplier approval and incoming inspection
- Premises: construction, fire protection, housekeeping, security, flood resilience
- Values: buildings/contents/stock and peak stock levels
- Business interruption: indemnity period assumptions and continuity plans
- Chemicals/waste streams: storage and environmental controls (where relevant)
Insure24 can help you package this information into an “underwriter-ready” summary and advise which covers are essential vs optional for your specific operation. The outcome is usually faster quotes, fewer exclusions, and a clearer renewal process.
We supply flex-rigid boards into high-reliability applications and needed clarity on product liability, recall exposure and overseas territory. Insure24 helped us structure a programme that aligned to OEM requirements and made renewal far smoother.
Operations Manager, UK Flex PCB ManufacturerHow to Get a Quote for Flexible & Flex-Rigid PCB Insurance
Many PCB risks are quotable quickly when the submission is clear. More complex businesses (export, high-hazard sectors, large contract limits, or specialist process hazards) may require underwriter review. As a guide, allow 1–2 business days for a full underwriter response once the core information is provided.
If you are renewing, start early. Manufacturers often benefit from a structured presentation of changes: growth, new customers, new territories, upgrades to fire protection, improved QA controls, and updated valuations. Underwriters respond well to clear evidence and stability.
What We’ll Ask You For
- A short description of products and processes (flex, flex-rigid, assembly/test)
- Turnover split by product and territory (including export/resale routes)
- Premises details, fire protection and security measures
- Declared values for stock, contents, plant and machinery
- Claims history and any incidents (product, property, cyber, environmental)
- Any key contract requirements (limits, endorsements, supplier clauses)
How Insure24 Adds Value
- We translate your technical operation into underwriter language
- We help avoid gaps: recall, PI, pollution, territory and cyber
- We can structure combined packages for simplicity and consistency
- We help align cover with OEM contract requirements
- We support mid-term changes (MTAs) and renewals as you grow
- We help create a clean “risk story” to secure better terms
FREQUENTLY ASKED QUESTIONS
+-
Is flexible PCB manufacturing insured differently to rigid PCB manufacturing?
Often, yes. Flexible and flex-rigid products can introduce different failure modes (bending fatigue, adhesion, coverlay performance, dimensional stability),
and they are frequently used in higher consequence applications. Insurers may focus more on process controls, traceability and customer sectors.
+-
Does product liability cover the cost of replacing faulty boards?
Typically not. Product liability is generally designed for third-party injury or third-party property damage caused by your product.
The cost to replace your own products and run field actions is usually addressed by specialist product recall/rectification cover (if arranged),
subject to policy wording.
+-
When would a PCB manufacturer need professional indemnity insurance?
If you provide design input, stack-up guidance, specification sign-off, engineering advice, performance representations (impedance, bend radius, dynamic flex life),
or documentation that customers rely on, professional indemnity may be appropriate. It is intended for professional negligence / financial loss style disputes,
subject to wording.
+-
How long should the business interruption indemnity period be for PCB manufacturing?
It depends on lead times and how quickly you could restart after a major event. Many manufacturers choose 12 months by default,
but flexible PCB operations may need longer due to specialist equipment replacement, controlled-area reinstatement, and customer re-qualification.
18–24 months (or more) can be appropriate in some cases.
+-
Do I need worldwide cover if I only sell in the UK?
Not always — but you should consider where your products may end up through resellers, distributors or OEM supply chains.
Some businesses have “silent” overseas exposure without direct exports. We can help you assess territories realistically and align cover.
+-
How quickly can Insure24 arrange flexible PCB insurance?
Some risks can be quoted quickly, but complex PCB manufacturers (export, high-reliability sectors, large contract limits, specialist hazards)
may require underwriter review. As a guide, allow 1–2 business days once core information is provided for a full response.
UNIQUE INSURANCE
TAILORED FOR YOU
Flexible and flex-rigid PCB manufacturing combines high-value materials, controlled processes and higher consequence product exposure. Speak to Insure24 to build a practical programme that protects your factory, your cashflow and your liability position — aligned to how you manufacture and sell.
PROTECT YOURSELF
- Property and materials cover for specialist PCB facilities
- Business interruption protection built around realistic recovery timelines
- Public and product liability aligned to your sectors and territories
- Options for PI, recall/rectification, environmental and cyber exposures
- Support presenting your technical risk to underwriters for better terms