Are there any tougher materials than pure copper?
Well, there are many materials that are tougher. Inconel for instance is a very hard metal. However, you are going to get a lot of resistance, and you are going to basically make a heater if you put any kind of current through it at all. Really from a toughness standpoint, rolled annealed copper is probably your best bet because it is soft and has high elongation. It can stand an awful lot before it breaks. Keep track of what you are doing with the circuit before and while you install it, and make sure that you are not exercising it beyond its limits. Are there instances where you would not want to put a strain relief fillet on a flex with stiffener? I would say that if you are not bending it near the stiffener, it is not necessary. It would just be a cost adder. If your stiffener is extremely thin, the strain relief fillet could actually be detrimental. If you have a five mil thick stiffener on your circuit, there is no way you can put a five mil thick fillet. What happens is that you
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