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94v0 LED PCB Assembly: How We Ensure Quality in Every Step?
Monday, August 4th, 2025

If you are developing lighting products, displays, or electronic devices that use LEDs, then LED PCB assembly is a crucial step in turning your idea into a working product. Among many requirements, 94v0 LED PCB assembly is one of the most requested because of its fire-resistant properties. Whether used in indoor lighting, automotive systems, or industrial equipment, the quality of the assembly process plays a key role in how well an LED product performs and how long it lasts.

At Best Technology, we provide full turnkey LED PCB assembly services tailored to meet global quality standards. Our facility in China is certified to ISO9001, IATF16949, ISO13485, and AS9100D, so we can serve various industries. We support both prototypes and high-volume production and no minimum quantity requirements.

What is a LED PCB?

A LED PCB is a specialized circuit board designed to support and power LEDs efficiently. Unlike traditional PCBs, LED PCBs often require better thermal management because LEDs generate significant heat during operation. To solve this, metal core PCBs, especially aluminum-based PCBs, are commonly used for LED applications. These boards offer excellent heat dissipation and mechanical stability.

Key Features of LED PCBs:

  • Metal Core Base (Often Aluminum and copper): Helps manage heat generated by LEDs.
  • Copper Traces: Conduct electricity efficiently.
  • Solder Mask and Surface Finish: Protect the board and enhance durability.
  • Customized Shapes and Sizes: Designed based on the final product’s form.

LED PCBs are widely used in lighting fixtures, automotive headlights, backlit displays, signage, and industrial illumination systems. Their main advantage is efficient heat dissipation, which prolongs the LED’s lifespan and ensures consistent brightness.

LED PCB Without Components

LED PCB vs LED PCB Assembly

Understanding the difference between a LED PCB and LED PCB assembly helps clarify the scope of your project needs.

  • A LED PCB refers to the bare printed circuit board that includes copper tracks and pads but no components mounted on it.
  • LED PCB assembly is the full process of mounting LEDs and other electronic parts on the PCB to make it functional.

If you only order the PCB, it won’t work until it goes through the assembly process. At Best Technology, we handle both PCB fabrication and LED PCB assembly, saving you time and reducing the risk of issues between design and production.

LED PCB Assembly with LED Chips

Detailed LED PCB Assembly Process

The LED PCB assembly process is a multi-stage procedure that demands strict quality control at every phase. Below is a detailed breakdown of how Best Technology handles LED PCB assembly from start to finish. We deeply know the importance of quality, so each step are well-controlled to ensure the final product performs reliably.

1. File Review and BOM Verification

Before anything begins, our engineers carefully review your Gerber files, Bill of Materials (BOM), assembly drawings and perform DFM check to ensure compatibility and avoid errors. If there are any problems, our guys will send approvements to you for approval and continue until get your confirmation!

2. Component Procurement and Inspection

The process begins with sourcing high-quality LEDs and supporting components like resistors, capacitors, and connectors. We work only with trusted suppliers like mouser, digikey, find chips to ensure that all components meet performance and safety standards. Upon arrival, all components undergo incoming quality control (IQC), including visual inspection, functional testing, and packaging verification. In Best Technology, we support partial components sourcing, that means you can provide components or provide partial components to us.

3. Solder Paste Printing

Solder paste is applied to the solder pads on the bare PCB using a stencil printer. This step is critical because the quantity and placement of solder paste directly influence the quality of the solder joints. We use automated stencil printing machines to apply the paste consistently across all boards, ensuring optimal solder volume and alignment. After printing solder paste, we will perform SPI inspection to make sure the evenly paste spreading.

4. SMT Pick and Place

Once the solder paste is printed, the board moves to the pick and place stage, where automated SMT machines precisely place each component on the board. LEDs must be correctly oriented and positioned to maintain consistent brightness and color uniformity. Our pick and place machines handle small SMD LEDs (01005 sizes) as well as larger power LEDs with high accuracy.

5. Reflow Soldering

The boards with placed components are passed through a reflow oven. The oven heats the board in a controlled temperature profile that melts the solder paste and solidifies the electrical connections. Each LED PCB requires a customized reflow profile to avoid damaging sensitive LEDs and ensure strong, void-free solder joints.

6. AOI Inspection (Automated Optical Inspection)

After reflow soldering, we perform AOI inspection using high-resolution cameras that scan the entire board for defects such as misaligned components, solder bridges, insufficient solder, or missing parts. AOI helps detect errors early, reducing rework and ensuring product reliability.

7. Functional Testing

Functional testing is essential for LED PCB assembly. We power up each board to verify that all LEDs light up properly, and test for brightness, color temperature, voltage, and current draw. Any boards that fail the test are isolated and analyzed to determine the cause.

Common LED PCB Assembly Defects and Analysis

Even with advanced machines and experienced engineers, LED PCB assembly can face challenges. Understanding common defects helps prevent quality issues and reduce product failure in the field. Below are typical types of defects, their causes, and how we address them.

  • Virtual Soldering (Cold Solder Joint)

This occurs when the solder doesn’t properly bond to the component lead or pad. It often happens due to oxidized leads, contaminated surfaces, or incomplete solder melting. These joints can lead to intermittent connections, flickering LEDs, or total circuit failure.

  • Pad Lifting

Prolonged heating or excessive temperature during rework may cause the copper pad to detach from the PCB substrate. This defect is common when the PCB lacks proper thermal resistance or heat treatment was not controlled during manufacturing.

  • Solder Bridging (Short Circuit)

When too much solder paste is applied or components are placed too closely, it can create a bridge of solder between adjacent pins or pads. This causes unexpected electrical connections, leading to short circuits or component failure.

  • PCB Warping or Cracks

Improper material selection, uneven thermal expansion, or poor lamination techniques can cause the board to warp or crack. This leads to misalignment of components and can even cause open circuits due to mechanical stress.

  • Moisture Absorption

If the PCB is not properly baked before assembly, it may retain moisture. During reflow soldering, trapped moisture vaporizes, forming bubbles or delamination, which can damage internal layers or cause short circuits.

  • Poor Heat Dissipation

LEDs generate heat, and insufficient thermal design—such as no heat sink, poor copper thickness, or inadequate via design—can lead to LED overheating, early lumen degradation, or even component burn-out. This is critical in high-power LED assemblies.

  • Inadequate Spacing Between Traces or Pads

If the design leaves insufficient spacing between LED pins or traces, it raises the risk of short circuits during soldering, especially with high current LED applications.

  • Misalignment Between PCB Layers

In multi-layer LED PCBs, improper consideration of thermal expansion coefficients or misalignment during layer stacking may cause warping during soldering, affecting overall reliability.

  • No Pre-Baking

Flexible LED strips or moisture-sensitive components should be pre-baked before soldering. Skipping this step may result in component cracking, color variation, or reduced LED lifespan.

Common LED PCB Assembly Defects and Analysis

How We Prevent These Defects?

At Best Technology, we take proactive measures to reduce these risks:

  • Design Optimization: We assist clients with DFM (Design for Manufacturability) to improve spacing, heat dissipation, and alignment.
  • Controlled Processes: We monitor solder paste thickness, reflow oven temperature, and component placement accuracy using real-time SPC systems.
  • Material Handling: All PCBs are pre-baked to remove moisture, and we use appropriate solder pastes based on the design and LED type.
  • Inspection and Testing: AOI, X-ray, and functional testing help us catch any defect early and ensure that each LED assembly works correctly

How We Ensure the Highest Quality During LED PCB Assembly?

At Best Technology, delivering high-quality LED PCB assemblies is our top priority. Here’s how we maintain consistent quality:

  • Advanced Equipment

We invest in automated and high-precision machines for every step of assembly. Our AOI systems, reflow ovens, and pick and place machines are regularly maintained and calibrated to ensure accuracy.

  • Skilled Technicians and IPC Standards

All assembly work is carried out by trained personnel who follow IPC-A-610 standards for electronic assemblies. Our team’s experience helps us tackle complex assemblies with confidence.

  • MES System and Traceability

We use a Manufacturing Execution System (MES) to monitor production in real-time. Each board has a unique traceability code, allowing us to track its production history, components used, and test results.

  • Quality Audits and Final Inspection

Before shipping, every batch undergoes final quality control (FQC), including random sampling and full functional testing. This ensures that our customers receive only fully functional and reliable LED PCBs.

LED PCB Assembly Machines We Use

Reliable LED PCB assembly depends on the quality of equipment used. At Best Technology, we invest in modern assembly machines that allow for fast, accurate, and repeatable results. Our equipment includes but not only:

  • Yamaha & Juki Pick-and-Place Machines
  • Solder Paste Printers (Fully Automated)
  • 3D SPI Inspector
  • Nitrogen Reflow Oven
  • Dual Online AOI Machine
  • X-ray Inspection
  • FAI tester
  • PT-500M-2ABN loader
  • Dry Ice Cleaner
  • Selective Wave Soldering
  • Multiply Aging Testing
LED PCB Assembly Machines We Use

Our 94v0 LED PCB Assembly Daily Capabilities

94v0 LED PCBs are manufactured using flame-retardant materials that meet UL94V-0 standards. This rating indicates that the material self-extinguishes quickly after being exposed to a flame, which is crucial for safety. Here’s what we offer daily:

  • Daily Output: Up to 10,000 LED PCBs depending on complexity.
  • Board Types: Rigid, flexible, aluminum-core, and copper-core boards.
  • LED Options: Standard SMD LEDs, COB (chip on board), and high-power LEDs.
  • Applications: LED lighting fixtures, automotive lights, medical devices, signage, and industrial systems.
  • Customization: We support custom shapes, multiple layers, and specialized surface finishes.
  • Minimum Order Quantity: No strict MOQ; we accept small-batch and large orders.
  • Prototyping Speed: 3–5 working days for prototypes.

China LED PCB Assembly Manufacturer – Best Technology

When it comes to LED PCB assembly in China, having a dependable partner can make a big difference in your product’s quality, lead time, and overall success. At Best Technology, we specialize in delivering high-quality LED PCB assembly services tailored to your needs—whether you’re developing lighting systems, automotive LEDs, or consumer electronics.

Here’s why companies worldwide choose us:

  • One-stop Service: From PCB fabrication to full assembly, testing, and packaging, we handle every step in-house.
  • Fast Turnaround: Whether you need prototypes or large-scale production, we offer quick turnaround times, clear communication, and reliable delivery.
  • Competitive & Transparent Pricing: Direct factory pricing with no hidden costs.
  • Professional Support at Every Stage: Our experienced engineers help with design review, material selection, and process optimization, so your project runs smoothly from start to finish.
  • Flexible Order Quantities: We handle both prototyping and mass production with equal attention to detail.
  • Smart Manufacturing: With our MES system, we track every board throughout production, giving you full traceability and confidence in product quality.

If you’re looking for a China-based LED PCB assembly manufacturer that delivers quality, speed, and peace of mind, Best Technology is here to support you. Contact us today for a quote or to discuss your next project—we’re ready to help.

FAQs

1. What does 94v0 mean in LED PCB assembly?

It’s a UL rating for flame-retardant PCBs, meaning the material self-extinguishes after ignition, ensuring safer products.

2. What is the difference between aluminum and FR4 for LED PCBs?

Aluminum provides better heat dissipation and is ideal for high-power LEDs. FR4 is suitable for low-power or budget-friendly applications.

3. What types of LEDs can you assemble?

We assemble SMD LEDs, COB LEDs, high-power LEDs, and custom LED arrays for various applications.

4. How do you ensure the LEDs won’t overheat?

We use metal core PCBs, apply thermal pads, and follow optimized reflow profiles to manage heat effectively.

5. Do you offer testing for assembled LED PCBs?

Yes, we offer functional testing, burn-in testing, and optional aging tests for long-term reliability.

6. What’s the typical lead time for LED PCB assembly?

Prototypes: 3–5 working days; volume orders: 7–15 days depending on complexity.

7. Do you support custom designs?

Yes, we support custom LED PCB designs, including unique shapes, sizes, and special surface finishes.

8. How can I get a quote for LED PCB assembly?

You can send us your Gerber files, BOM, and specifications. Our team will provide a clear, competitive quote within 24 hours.

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What is an aluminium PCB circuit board? Metal core PCB
Monday, August 4th, 2025

An aluminium PCB circuit board, or metal core PCB, is a type of circuit board built on an aluminum base for better heat dissipation. Unlike standard FR-4 boards, it handles high temperatures and heavy loads with ease.

It’s commonly used in LED lighting, automotive systems, and power electronics where performance and durability matter.

What is an aluminum PCB circuit board? Metal core PCB

How to make aluminum PCB?

Making an aluminium PCB circuit board involves several precise steps. Each layer plays a role in the board’s thermal, electrical, and structural performance.

  • Aluminum Base Layer: This is the bottom layer and acts as the backbone. It’s made from high-quality aluminum alloy that’s strong, lightweight, and thermally conductive.
  • Dielectric Layer: This insulating layer sits between the aluminum and copper. It transfers heat efficiently while keeping electrical signals safe.
  • Copper Layer: This is where the actual circuitry is formed. Copper is etched to create the pathways that electrical signals follow.
  • Solder Mask and Silkscreen: The solder mask protects the copper from oxidation and short circuits. The silkscreen marks component placements and part numbers.
  • Drilling & Surface Finishing: Holes are drilled for component leads. Surface finishes like ENIG or HASL are applied to improve solderability.

Every step demands precision. At Best Technology, we fine-tune this process to create aluminum PCBs that meet strict quality standards.

What is the structure of aluminum PCB?

The structure of an aluminum circuit board is simple but effective:

  • Metal Core (Aluminum Layer): Offers mechanical strength and heat sinking.
  • Thermal Dielectric Layer: Transfers heat away from the copper layer.
  • Copper Circuit Layer: Routes the signals and power across the board.

Depending on the design, it can be:

  • Single-layer: Common for LED applications.
  • Double-layer: For more complex circuits.
  • Multilayer: Combines performance and compact size.
  • Rigid-flex: For advanced or tight-space applications.

Each type supports different applications but shares the same core benefit—effective thermal management.

How thick is aluminum PCB?

The thickness of an aluminium PCB circuit board varies based on the application:

  • Aluminum Base Layer: Typically ranges from 0.8mm to 3.2mm.
  • Copper Layer: 1oz to 3oz (35ÎŒm to 105ÎŒm).
  • Dielectric Layer: Between 100ÎŒm and 200ÎŒm.
What is an aluminum PCB circuit board? Metal core PCB

Thicker boards offer better heat dissipation and mechanical strength, while thinner boards save space and cost. The right choice depends on power levels, component density, and enclosure design.

What is the maximum temperature for aluminum PCB?

Aluminum PCBs are designed to handle heat with ease. In most cases, they can operate continuously between 130°C and 150°C. During brief soldering processes, they can withstand up to 250°C.

This makes them perfect for high-temperature environments, especially in LED lighting and power electronics. But, performance depends on:

  • Copper weight
  • Quality of the dielectric layer
  • Circuit design and cooling system

At Best Technology, we choose high-grade materials to ensure long-lasting temperature stability.

What are the pros and cons of aluminum PCB?

Let’s start with the advantages:

  • Superior Heat Dissipation: Heat moves quickly away from sensitive parts. This boosts performance and extends product life.
  • Lightweight Yet Durable: Aluminum is stronger than FR-4 and lighter than ceramic boards.
  • Longer Lifespan: Better thermal handling reduces component failure rates.
  • Eco-Friendly: Aluminum is recyclable, reducing environmental impact.
  • Cost-Effective for Power Applications: Reduces need for extra heat sinks and thermal pads.
What is an aluminum PCB circuit board? Metal core PCB

And now the few limitations:

  • Not as flexible as polymer-based PCBs
  • Slightly higher initial cost than FR-4 (but lower maintenance and longer lifespan)

In real-world use, the advantages far outweigh the disadvantages, especially since it is designed and manufactured by BEST Technology.

What is the difference between aluminum and FR-4 PCB?

Let’s compare the two:

FeatureAluminum PCBFR-4 PCB
Thermal ConductivityHigh, handles heat wellLow, needs heat sinks
MaterialMetal core (Aluminum)Fiberglass epoxy (FR-4)
DurabilityTough, resists shockLess impact-resistant
Cost (initial)Slightly higherLower
Cooling AccessoriesOften not neededFrequently needed
WeightModerateLightweight

If your project involves high power or heat-sensitive components, aluminum wins hands down.

When to use aluminum PCB?

Aluminum PCBs aren’t for everything, but when heat is involved, they’re unbeatable.

Use them in:

  • LED lighting (especially high-brightness)
  • Power supply modules
  • Automotive electronics
  • Electric vehicle components
  • Communication base stations
  • Audio amplifiers

They’re also great when you want to reduce size and weight without sacrificing strength.

What are aluminum PCBs used for?

These boards are everywhere, though often hidden inside devices:

  • 1. LED Applications: LEDs produce heat, and aluminum PCBs are ideal for pulling that heat away. This prevents light degradation and extends lifespan.
  • 2. Automotive Systems: Cars generate vibration, heat, and require stability. Aluminum PCBs resist shock and stay cool—perfect for control modules and lighting.
  • 3. Power Electronics: Used in DC/AC converters, battery management systems, and solar inverters.
  • 4. Industrial Controls: Drive controllers, motor regulators, and sensors need tough, reliable PCBs. Aluminum handles the stress and heat like a pro.
  • 5. Medical Equipment: From diagnostic machines to surgical lighting, these boards maintain performance and safety in critical conditions.
  • 6. Telecommunication Systems: They provide reliability in routers, amplifiers, antennas, and base stations.
What is an aluminum PCB circuit board? Metal core PCB

Aluminum PCBs support modern devices across industries, from smart homes to renewable energy systems.

Conclusion:

Aluminium PCB circuit boards bring the perfect mix of strength, efficiency, and thermal control. They handle harsh environments and extend the lifespan of electronics. Their use in electronic products is increasing due to their superior thermal management, improved durability and long-term cost-effectiveness.

At Best Technology, we specialize in high-performance aluminum PCB design and manufacturing. Our boards are built to meet international standards and customized to your needs.

Want to upgrade your products with dependable aluminum PCBs? Contact us today at: sales@bestpcbs.com

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Bare Copper PCB, Blank Copper PCB Board Manufacturer
Friday, August 1st, 2025

What is bare copper PCB? Let’s explore its benefits, applications, design guide, design spec, manufacturing process, manufacturer selection methods.

Are you worried about these problems?

  • Is your device overheating and throttling? — Do traditional FR-4 boards always force you to prioritize cooling under high load?
  • Is heat generation high in a small space? — In the pursuit of thinness and lightness, are performance or reliability sacrificed due to insufficient heat dissipation?
  • Is cooling cost difficult to control? — Does adding heat sinks and fans increase the BOM cost with limited effectiveness?

Best Technology can provide solutions

  • Metal-Based Thermal Conductivity: Aluminum/copper substrates offer 5-10 times higher thermal conductivity, enabling rapid heat dissipation and stable operation in high-temperature environments.
  • Compact Design: Integrated metal-based molding eliminates the need for additional heat dissipation components, improving space utilization by 30%.
  • Total Cost Optimization: Reduces procurement and assembly costs for cooling modules, reducing overall lifecycle costs by 20%.

Welcome to contact us if you have any request for copper base PCB: sales@bestpcbs.com.

What Is Bare Copper PCB?

A Bare Copper PCB is an uncoated circuit board where the raw copper layer remains fully exposed. Stripped of traditional surface finishes like gold or tin plating, this design maximizes copper’s inherent properties, exceptional conductivity (5.9×10⁷ S/m) and thermal dissipation (400W/m·K). Ideal for high-frequency applications like 5G and power electronics, it offers cost savings (15-20% reduction) while maintaining signal integrity by eliminating plating-induced signal loss.

What Is Bare Copper PCB?

What Are Advantages of Blank Copper PCB?

  • Cost Efficiency – No additional surface finish (e.g., ENIG, HASL) reduces manufacturing costs by 15–30%.
  • Superior Conductivity – Pure copper provides low resistance, ideal for high-speed signals and low-loss power transmission.
  • Enhanced Thermal Performance – Natural copper thermal conductivity (385 W/m·K) efficiently dissipates heat in high-power applications.
  • Design Flexibility – Untreated surface allows easy modification (e.g., etching, soldering) during prototyping or customization.
  • Environmental Compliance – Avoids chemical coatings, reducing hazardous waste and aligning with RoHS/REACH standards.
  • Rapid Prototyping – Simplified production process shortens lead times for testing and iterative design.
  • Mechanical Durability – Thick copper layers (e.g., 2oz/70ÎŒm) resist warping and physical stress in rugged environments.
What Are Advantages of Blank Copper PCB?

What Are Applications of Blank Copper PCB Board?

  • Prototyping & Rapid Iteration: Cost-effective for testing circuit designs before finalizing surface finishes.
  • High-Power Electronics: Used in power supplies, motor controllers, and LED drivers for efficient heat dissipation.
  • RF/Microwave Circuits: Ideal for antennas, filters, and amplifiers due to low signal loss from pure copper.
  • Custom DIY Projects: Flexible for hobbyists to modify traces, solder components, or experiment with layouts.
  • Thermal Management Systems: Integrated into heat sinks, LED backlights, or high-current connectors.
  • Educational & Training Tools: Teaches PCB basics, soldering, and circuit design without complex coatings.
  • Eco-Friendly Devices: Suits RoHS-compliant products avoiding chemical finishes (e.g., medical devices).

Bare Copper PCB Design Guide

1. Material Selection

  • Substrate: FR4 (general-purpose), polyimide (high-temperature/flexible), aluminum substrate (high-thermal).
  • Copper Thickness: 0.5oz (17ÎŒm) to 3oz (105ÎŒm), tailored to current requirements (2oz supports ~2A/mm).

2. Layer Stackup

  • Recommended 4-Layer Structure: Signal layer – ground layer – power layer – signal layer, ensuring low-impedance paths.
  • Ground Plane Priority: Assign dedicated ground planes in inner layers; minimize signal loop areas.

3. Thermal Management

  • Copper Layout: Use wide copper traces (≄1.5mm width) for high-current zones; leverage copper’s thermal conductivity (385 W/m·K).
  • Thermal Vias: Add thermal vias (0.3mm diameter, 30ÎŒm plating) to connect copper layers and dissipate heat.

4. ESD Protection

  • Grounding: Cover critical areas with ground planes; connect connector shells to isolated ground pads via short traces.
  • Protection Devices: Place TVS diodes (≄15kV) near I/O ports; keep TVS-to-ground paths ≀2mm.
  • Layout Isolation: Keep sensitive components (e.g., CMOS ICs) away from board edges; use copper rings for shielding.

5. Manufacturing & Compliance

  • Copper Thickness Tolerance: Control etching accuracy (±10%) to avoid impedance deviations.
  • RoHS Compliance: Prohibit lead/mercury; use halogen-free substrates.

6. Signal & Power Design

  • Signal Traces: Route high-speed signals adjacent to ground planes; match differential pair impedance (90–100Ω).
  • Power Distribution: Use wide copper traces (≄2mm) for low voltage drop; place decoupling capacitors (0.1ÎŒF) near power pins.

7. Testing & Validation

  • ESD Testing: Meet IEC 61000-4-2 standards (contact 8kV, air 15kV).
  • Thermal Simulation: Validate high-current area temperature rise (target ≀10°C).
Bare Copper PCB Design Guide

Bare Copper PCB Design Specification

CategorySpecification
Surface FinishUncoated bare copper (oxidation prevention recommended)
ElectricalConductivity: 5.9×10⁷ S/m Current Capacity: 30% higher than coated traces
ThermalThermal conductivity: 400W/m·K Max operating temp: 150°C (continuous)
Design RulesMin trace width: 6mil (0.15mm) Min hole size: 0.25mm
Layer OptionsSingle/Double-sided only (multilayer requires special processing)
Signal IntegritySkin effect optimized for >10GHz RF applications
ManufacturingRequires: – No-plate drill process – Direct copper bonding

Blank Copper PCB Manufacturing Processes

1. Design & Layout: Generate Gerber files with copper trace widths, spacing, and layer stackup (single/double-sided or multilayer).
2. Material Preparation: Cut substrate (FR4, polyimide, or aluminum) to board size. Apply adhesive for multilayer boards.
3. Drilling: Use CNC to drill via/component holes. Tolerance: ±0.05mm.
4. Through-Hole Plating: Electroplate copper into holes (thickness: 15–25ÎŒm) to connect layers.
5. Outer Layer Imaging: Coat with photoresist, expose to UV through artwork mask, develop to define traces.
6. Etching: Remove unprotected copper using alkaline etchant (e.g., ammonium persulfate).
7. Solder Mask (Optional): Apply liquid photoimageable solder mask, expose, and develop to protect copper.
8. Testing: Electrical test (flying probe/fixture) for shorts/opens. AOI inspection for trace integrity.
9. Routing & V-Scoring: Cut board to final dimensions using CNC router.
10. Packaging: Vacuum-seal boards with desiccant to prevent oxidation.

Blank Copper PCB Manufacturing Processes

How to Choose A Blank Copper PCB Manufacturer?

Methods about how to choose a bare copper PCB manufacturer:

Technical Capability Verification: Layer & Copper Thickness

  • Confirm support for multi-layer boards (e.g., 12–40 layers) and thick copper (≄2oz/70ÎŒm). Check minimum trace width/spacing (e.g., 3mil/0.0762mm) and via diameter (≄0.2mm).

Certification & Compliance

  • Prioritize manufacturers with ISO 9001 (quality), UL (safety), IATF 16949 (automotive), and RoHS (environmental) certifications. Ensure compliance with IPC-6012 (rigid PCB performance) and MIL-P-13949G (military/aerospace) if applicable.

Production Capacity & Delivery

  • Prototyping Speed: Look for 24-hour prototyping or faster for urgent projects.
  • Scalability: Ensure capacity for mass production (e.g., multiple automated production lines).

Quality Control

  • Testing: Require electrical testing (flying probe/fixture) and AOI inspection for defect detection.
  • Material Control: Verify copper thickness tolerance (±10%) and substrate quality (FR4/polyimide).

Industry Experience

  • Choose manufacturers with proven expertise in your sector (e.g., automotive, medical, or high-speed designs). Review case studies or client testimonials for validation.

Cost & Supply Chain

  • Compare pricing models for small/medium batches. Opt for manufacturers with scalable production to reduce per-unit costs. Consider geographic proximity to minimize logistics expenses.

Communication & Support

  • Assess responsiveness to technical queries and post-sales service. Ensure clear warranty terms and defect resolution processes.

Step-by-Step Selection Process

  • Define Requirements: Specify layer count, copper thickness, delivery timeline, and certifications.
  • Shortlist Candidates: Use industry directories or trade platforms to filter by capabilities.
  • Request Quotes & Samples: Provide design files for cost estimation and test sample evaluation.
  • Audit Factories: Inspect equipment (e.g., automatic plating lines) and quality control processes.
  • Pilot Order: Place a small order to validate quality and delivery reliability.
  • Finalize Partnership: Negotiate contracts with manufacturers meeting all criteria.

How to Get A Quote For Copper PCB Project?

Required Documents for Quote:

1. Design Files

  • Submit Gerber files (RS-274X format) with layer stackup, copper traces, and drill data.
  • Include BOM (Bill of Materials) if components are pre-sourced.

2. Technical Specifications

  • Board Details: Dimensions, layers (single/double/multilayer), copper thickness (0.5oz–3oz).
  • Material: FR4, polyimide, or aluminum substrate.
  • Surface Finish: Specify bare copper or optional coatings (ENIG, HASL).

3. Quantity & Deadline

  • Provide order volume (prototypes, small batch, or mass production).
  • Clarify delivery timeline (urgent orders may incur priority fees).

4. Special Requirements

  • Highlight ESD protection, thermal via density, or compliance standards (RoHS, UL).

Why Choose Best Technology?

  • Expertise: 19+ years in copper PCBs, supporting 40-layer boards and 6oz thick copper.
  • Speed: 2-hour quote response and 24-hour prototyping.
  • Quality: Full IPC-6012 compliance and AOI/electrical testing.

Contact us now if you have any request for metal core PCB: sales@bestpcbs.com.

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What is Exposed Copper on PCB​? PCB Exposed Copper Edge
Friday, August 1st, 2025

When looking at a printed circuit board (PCB), you may notice shiny areas of metal that aren’t covered by the usual green or colored solder mask. These are areas of exposed copper on PCB, and they serve important roles in how the board functions. Exposed copper can be found on pads, traces, or even along the edges of the board. But why is the copper left uncovered? And how do you design a PCB to safely include exposed copper?

In this article, we’ll explore the meaning, purpose, types, and design considerations for exposed copper on PCB, including how to manage its risks and where it’s commonly used.

What is Exposed Copper on PCB​? PCB Exposed Copper Edge

What Does Exposed Copper on PCB Mean?

In a PCB, exposed copper refers to areas where the copper layer is intentionally left uncovered by solder mask or surface finish. Normally, copper traces and pads are coated with a protective layer to prevent oxidation and corrosion. However, in certain parts of the board, copper is left exposed for electrical or mechanical reasons.

You’ll typically see exposed copper in places where components need to be soldered or where the board makes direct contact with another surface, such as in connectors or test points. These areas must have direct electrical contact, and that means the copper needs to remain accessible.

Where Is Copper Usually Exposed?

  • Component pads: These areas must be exposed for soldering.
  • Test points: Used for measuring signals during testing.
  • Thermal reliefs: Copper areas used to help dissipate heat.
  • Edge connectors: Known as pcb exposed copper edge, these are found on plug-in boards.
  • Copper pours: Large copper areas, sometimes left exposed to improve thermal or grounding performance.

Purpose of Designing Exposed Copper on PCB

Designing with exposed copper is a common and often necessary practice. Below are some of the most common reasons designers choose to expose copper on a PCB.

1. Electrical Contact

Soldering requires exposed copper. All component pads, whether for surface mount or through-hole components, need to be bare so solder can properly adhere and form a good electrical connection.

In addition to pads, test points are exposed copper areas used during assembly and troubleshooting. Probes can be placed on these spots to measure voltages or signals.

2. Thermal Management

Copper is an excellent conductor of heat. In high-power applications, such as LED lighting, motor drivers, or power supplies, leaving copper exposed can help manage heat by allowing it to dissipate more efficiently. Large exposed copper plates can act like heat sinks.

3. Grounding and Shielding

In many designs, especially in radio frequency (RF) or high-speed digital circuits, exposed copper design PCB layouts include areas for grounding or electromagnetic interference (EMI) shielding. A pcb exposed copper edge can also be connected to ground and used as part of the shielding structure to protect signal integrity.

4. Cost Considerations

Leaving copper exposed in non-critical areas can reduce costs. Surface finishes like ENIG or HASL add expense, so in low-cost or temporary boards, some copper may be left bare to save on manufacturing steps.

What is Exposed Copper on PCB​? PCB Exposed Copper Edge

Types of Exposed Copper PCB Designs

There are several ways exposed copper is used in PCB layouts, each serving a specific function depending on the design goals. Below are the most common types you’ll find, along with their applications and things to watch out for.

1. Exposed Copper Pads

Exposed copper pads are the most widely used type of exposed copper in any PCB. These are the metal areas where components are soldered onto the board. By design, they must remain uncovered to allow solder to create a solid electrical and mechanical connection between the component leads and the PCB’s copper layers.

In addition to component soldering, some exposed pads are used for mechanical support or to connect heat-generating parts to large copper pours for better heat dissipation. Proper surface finish on these pads—such as HASL or ENIG—helps prevent oxidation and improves solderability.

2. Exposed Copper Traces

In some designs, traces (the thin copper lines connecting different components) are intentionally left exposed. This is less common than exposed pads, but it’s done in specific cases where designers need direct access to the trace for testing or where the trace carries high current and benefits from better heat dissipation.

One common use for exposed copper traces is creating test points. By leaving a section of trace uncovered, engineers can place probes directly on the trace during testing or troubleshooting.

3. PCB Exposed Copper Edge

A pcb exposed copper edge refers to copper that runs right to the edge of the PCB and remains exposed for functional use. This is typically found in boards that need to connect to sockets or other boards via edge connectors. In these cases, the copper along the edge acts as contact points and must remain exposed for reliable electrical connection.

This type of exposed copper is also used for grounding purposes. For example, in RF circuits or high-speed digital designs, the board edge may have exposed copper connected to ground to reduce electromagnetic interference (EMI). Some designs use edge plating, where the copper is plated along the entire edge of the board to create a continuous conductive path.

What is Exposed Copper on PCB​? PCB Exposed Copper Edge

What Is the Clearance of Copper to Edge of PCB?

When designing PCBs, copper-to-edge clearance is critical. Copper should not be placed too close to the edge unless it is meant to be exposed. If copper unintentionally gets too close to the edge, it can cause manufacturing problems or failures in the field.

Industry Guidelines

Standard practice, according to IPC standards, recommends at least 0.25mm (10 mils) clearance between copper and the board edge. This clearance prevents copper from being damaged or exposed during board cutting.

Edge Copper Design

If you’re designing a pcb exposed copper edge, such as for a connector or grounding point, you can extend copper to the edge, but it must be plated and processed correctly. Special instructions are needed for the manufacturer to plate the edges and prevent delamination.

How to Design a PCB with an Exposed Copper Plate?

Designing exposed copper areas requires planning and proper use of your PCB design software.

Step 1: Define Copper Areas

Use copper pours, pads, or large planes for the areas you want exposed. Ensure they are connected to the correct net, whether ground, power, or signal.

Step 2: Disable Solder Mask

In your PCB layout tool, disable the solder mask over these areas. This is done by creating a solder mask opening in the relevant layer.

Step 3: Edge Exposure

For pcb exposed copper edge designs, extend the copper to the edge of the board. Indicate this clearly in your mechanical drawings. Some manufacturers require a note to plate the edge.

Step 4: Selective Surface Finish

Decide whether the copper will remain bare or have a finish like HASL (Hot Air Solder Leveling) or ENIG (Electroless Nickel Immersion Gold). These finishes prevent oxidation and improve durability.

What is Exposed Copper on PCB​? PCB Exposed Copper Edge

Risks and Challenges with Exposed Copper PCB

While exposed copper on PCB serves many useful purposes, it comes with challenges.

Oxidation and Corrosion

Copper oxidizes quickly in air, forming a dull brown or green layer. This can reduce conductivity and make soldering difficult. Moist environments accelerate this process.

Short Circuits

Exposed copper is more likely to cause shorts if it touches other metal objects. Extra care is needed in design and assembly to avoid accidental contact.

Handling Risks

Bare copper areas can be scratched or contaminated during handling. Fingerprints, dust, or moisture can affect performance. Protective packaging and careful assembly help reduce these risks.

Exposed Copper Design Guidelines in PCB Layout

Here are some helpful tips for designing exposed copper areas safely:

  • Maintain clearance from high-voltage areas unless insulation is provided.
  • Use protective coatings like conformal coating if the board will be exposed to harsh environments.
  • Clearly indicate exposed copper areas in your Gerber files and fabrication notes.
  • For pcb exposed copper edge, work with your manufacturer to ensure proper plating and durability.
  • Use thicker copper (e.g., 2 oz) for large exposed areas meant for heat dissipation or high current.

FAQs

1. How to remove copper from PCB board?

Copper can be removed through chemical etching using ferric chloride or similar solutions. It can also be scraped off mechanically or milled with CNC tools.

2. What happens to exposed copper?

Exposed copper oxidizes when exposed to air and moisture. This can affect electrical performance, so protective finishes or coatings are often applied.

3. Can exposed copper PCB be used outdoors?

Not directly. Outdoor use requires additional protection, like conformal coating, to prevent corrosion. Without protection, copper will degrade quickly.

4. How do I prevent oxidation on exposed copper areas?

Apply coatings such as OSP (Organic Solderability Preservative), clear lacquer, or conformal coating. Using surface finishes like ENIG or HASL also helps.

5. What surface finish is best if I want partial copper exposed?

ENIG and HASL can be applied selectively. Masking during the finishing process allows partial copper exposure where needed.

6. Is exposed copper safe for high-voltage applications?

Not unless proper spacing and insulation are used. High voltage requires strict clearance and protection to avoid arcing or shorts.

7. What’s the difference between exposed copper and plated finish?

Exposed copper has no added layer, while plated finishes like ENIG or HASL add protection and improve performance.

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Copper Metal Core PCB Design Guide & Thermal Solution
Friday, August 1st, 2025

Looking for copper metal core PCB thermal solution? Let’s explore spec, benefits, application, design guide and thermal solution, manufacturing process for copper metal core PCB.

Are you worried about these problems?

  • Is your LED product experiencing luminous efficacy degradation due to insufficient heat dissipation?
  • How can you avoid reliability risks when high-power devices experience uncontrolled temperature rise?
  • Struggling to balance cost and performance? How can you choose a lightweight solution?

Best Technology can provide solutions

  • Precise Thermal Matching Service: Through thermal simulation modeling, we customize the copper layer thickness (available in 0.1-3.0mm), ensuring a 40% reduction in LED module junction temperature and a 50% reduction in lumen degradation.
  • High-Current Wiring Technology: Utilizing an immersion gold (Immersion Gold) + OSP process, it supports a continuous current of 5A/mmÂČ, eliminating overheating issues in power modules and increasing yield to 99.2%.
  • Lightweight Structural Design: Copper foil micro-etching technology achieves 50ÎŒm line/space widths. A multi-layer stacking solution reduces drone battery pack size by 20% and extends flight time by 15%.

Welcome to contact us if you have any request for metal core PCB: sales@bestpcbs.com.

What Is Copper Metal Core PCB?

A Copper Metal Core PCB (Printed Circuit Board) is a type of circuit board that uses copper as the base material instead of the traditional fiberglass (FR4). This metal core is typically located beneath the circuit layer and serves as a thermal conductor to dissipate heat generated by electronic components during operation. Copper metal core PCB has superior thermal conductivity, making it highly effective for managing heat in power electronics, LED lighting, automotive systems, and industrial control equipment.

What Is Copper Metal Core PCB?

Copper Metal Core PCB Specification

ParameterSpecification
Base MaterialCopper (typically C1100 or similar high-purity copper)
Copper Core Thickness0.5 mm, 1.0 mm, 1.5 mm, 2.0 mm, up to 5.0 mm (custom thickness available)
Circuit Layer Copper Thickness1 oz, 2 oz, 3 oz, up to 10 oz (35 ”m to 350 ”m)
Dielectric Layer Thickness0.05 mm to 0.5 mm
Thermal Conductivity of Dielectric1.0 W/m·K to 5.0 W/m·K or higher
Thermal Conductivity of Copper Core~400 W/m·K (excellent thermal performance)
Operating Temperature Range-40°C to +150°C or higher depending on design
Surface Finish OptionsHASL, ENIG (Electroless Nickel Immersion Gold), OSP, Immersion Tin/Silver
Solder Mask ColorGreen, White, Black (custom colors available)
Board SizeUp to 600 mm × 1200 mm (larger sizes possible upon request)
Drilling OptionsMechanical drilling, laser drilling for micro vias
Layer CountSingle-sided, double-sided, multilayer (up to 4 layers typical)
Impedance ControlAvailable for RF/high-frequency applications
Certification StandardsISO9001, UL, RoHS, IPC Class 2/3 compliant

Benefits of Copper Substrate PCB  

  • Exceptional Heat Dissipation: Copper’s high thermal conductivity (2x aluminum) rapidly transfers heat away from components, preventing overheating in LEDs, power modules, or automotive systems.
  • Longer Device Lifespan: Reduces thermal stress and component failure, extending reliability for high-current applications like EV chargers or industrial equipment.
  • Compact Design Flexibility: Thick copper layers enable dense circuits and smaller boards, saving space in 5G devices, RF systems, or medical electronics.
  • Cost-Effective Performance: Minimizes need for external cooling parts (fans/heatsinks), lowering long-term maintenance and material costs.
  • Versatile Application Fit: Ideal for high-power (solar inverters), precision (aerospace), and EMI-sensitive (radar) designs, ensuring stable operation in extreme environments.
Benefits of Copper Substrate PCB  

Applications of Copper Metal Core PCBs

  • High-Power LED Lighting: Efficiently dissipates heat from dense LED arrays, preventing color shift and extending lifespan for automotive, industrial, and architectural lighting.
  • Automotive Electronics: Manages heat in power modules (e.g., engine control units, battery management systems) under extreme temperatures, enhancing reliability for EVs and hybrid vehicles.
  • 5G & RF Devices: Supports high-frequency circuits and millimeter-wave components by minimizing thermal noise, critical for 5G base stations and radar systems.
  • Industrial Power Systems: Withstands high currents and thermal stress in motor drives, inverters, and solar power converters, reducing downtime and maintenance costs.
  • Aerospace & Defense: Provides lightweight, durable thermal management for avionics, satellite components, and ruggedized communication gear in harsh environments.

Copper Metal Core PCB Design Guide

Below is copper metal core PCB design guide:

1. Material & Substrate Selection

  • Use copper-core substrates (thermal conductivity ≄2W/mK) or ceramic substrates (AlN, 320W/mK). Avoid FR4.
  • High-power areas: 3-4oz copper; peripheral zones: 2oz. Transition zones use teardrop shapes (≀45°).
  • Ensure lead-free solder (SAC alloy), halogen-free laminate, and RoHS/REACH compliance.

2. Thermal Management

  • Spread high-power components (e.g., power ICs) to prevent heat buildup. Place heat-generating parts on outer layers for direct cooling.
  • Thermal vias: 0.3mm diameter, ≄4 vias/cmÂČ, 30ÎŒm copper plating. For IGBTs, embed 1.5mm heat pipes (local temp rise ≀15°C).
  • Add 10ÎŒm graphene film on copper layers to boost thermal diffusion by 40%. Validate designs with ANSYS/Flotherm and IR thermography.

3. Stack-Up & Board Thickness

  • For RF circuits, use Rogers RO4000 (Dk=3.38). Multi-layer boards: 6 layers reduce crosstalk by 60-70% vs. 4 layers. Apply 20H rule (power plane indented 20× layer spacing).
  • Standard thickness: 1.6mm; use ≄2.0mm for high-power applications.
  • Maintain >85% copper uniformity. Blind/buried vias reduce thermal stress by 30%.

4. Routing & Signal Integrity

  • Track width: 1mm (1oz copper) = 1A. Widen tracks for high current (1A/0.3mm). Prioritize power traces to minimize impedance.
  • High-speed signals: 3W spacing, matched lengths, 135° bends. Crystal circuits: Ground enclosure with stitching vias.
  • Route critical signals (e.g., clocks) first. Bridge splits with 0.1ÎŒF + 10ÎŒF capacitors.

5. Vias & Solder Mask

  • Laser vias: ≄0.1mm; mechanical vias: ≄0.2mm. Tolerance ±0.05mm (≀0.8mm vias). High-speed vias: Stub length <10mil; back-drill tolerance ±2mil.
  • Solder mask: Expand 0.05-0.1mm beyond pads. For BGAs, use NSMD (mask opening 15-25ÎŒm larger than pad). Remove mask in thermal zones.

6. Manufacturing & Testing

  • Hole aspect ratio (diameter:total thickness) ≀10:1. Metal-base tolerance: ±0.1mm; add 0.3mm vent holes per 20×20mm.
  • Reliability tests: Environmental: Thermal cycle (-40°C/+125°C), 95%RH/40°C/96h. Mechanical: Tensile strength >10N; peel strength ≄1.0N/mm.
  • Electrical: Contact resistance (mΩ-Ω range); insulation >10⁷Ω; HiPot.

7. Special Applications

  • High-power modules: Step-down copper (4oz core, 2oz periphery); embed AlN or heat pipes.
  • Flex designs: Rigid-flex follows rigid rules; keep 1.5-2mm clearance from SMD outlines.
  • Low-temperature: Use high-Tg substrate (Tg>170°C); increase via density.
Copper Metal Core PCB Design Guide

Copper Metal Core PCB Thermal Solution

1. Advanced Thermal Materials

  • Graphene-Enhanced Copper: Utilize copper-graphene composites (thermal conductivity up to 440W/mK) for core heating zones. Apply 10ÎŒm graphene films on copper layers to boost lateral thermal diffusion by 40%.
  • Staged Copper Thickness: Use 4oz copper for high-power areas (e.g., IGBTs), transitioning to 2oz in peripheral zones via teardrop-shaped (≀45°) connections.

2. Via Array Optimization

  • Thermal Vias: Deploy 0.3mm diameter vias in hotspots (density ≄4 vias/cmÂČ), reducing thermal resistance by 90% compared to non-via designs.
  • Dynamic Spacing: Use hexagonal via patterns for heat flux >50W/cmÂČ; rectangular arrays for <30W/cmÂČ. Maintain via spacing ≄2×via diameter +0.1mm.
  • Copper-Via Synergy: Thicken via walls to ≄30ÎŒm when outer-layer copper exceeds 35ÎŒm. Reduce via spacing to 0.8mm for 35ÎŒm copper layers.

3. Heat Pipe Integration

  • Embedded Heat Pipes: Insert 1.5mm-diameter heat pipes beneath IGBTs, filled with phase-change material. Limits local temperature rise to ≀15°C (5× more efficient than vias alone).
  • Patent-Proven Designs: Fix heat pipes to aluminum substrates via high-temperature soldering, ensuring direct contact with chassis for efficient heat dissipation.

4. Thermal Path Engineering

  • Vertical-Horizontal Hybrid Cooling: Combine 0.3mm vias (vertical heat transfer) with 0.5mm linewidth hexagonal grids (horizontal spreading) in non-critical zones.
  • Ceramic Insertion: Embed AlN ceramic pads (thermal conductivity 320W/mK) under power modules, bonded with silver paste to achieve baseplate thermal resistance <0.15°C/W.

5. Simulation & Validation

  • Thermal Modeling: Use ANSYS Icepak with 3× denser mesh in via regions. Validate against real-world data (e.g., 48V DC/DC module via optimization reduced thermal resistance from 1.2°C/W to 0.78°C/W).
  • Infrared Testing: Confirm design efficacy via thermal imaging, ensuring peak junction temperatures stay below 125°C (with <10°C rise per 10% power increase).

6. Manufacturing Adjustments

  • Aspect Ratio Control: Maintain via diameter-to-board thickness ratio ≀10:1. Tolerance: ±0.05mm for vias ≀0.8mm.
  • Solder Mask Management: Expand solder mask 0.1mm beyond pads; remove mask entirely in thermal via arrays to enhance heat dissipation.

How to Make A Copper Metal Core PCB?

1. Material Preparation

  • Substrate Selection: Choose copper-core substrates (thermal conductivity ≄2W/mK) or ceramic substrates (AlN, 320W/mK). Avoid FR4.
  • Copper Foil: Use 3-4oz copper for high-power areas; 2oz for signal layers. Pre-treat copper surfaces for adhesion.
  • Auxiliary Materials: Prepare dry film, solder mask ink, and semi-cured sheets (PP) for lamination.

2. Inner Layer Fabrication

  • Surface Cleaning: Clean substrates to remove oils, oxides, and contaminants.
  • Dry Film Application: Lamination of photosensitive dry film on copper surfaces.
  • Exposure & Development: UV exposure transfers circuit patterns to the dry film. Unexposed areas are dissolved in developer solutions.
  • Etching: Remove unprotected copper using alkaline etchants (e.g., ammonium persulfate).
  • AOI Inspection: Automatic Optical Inspection (AOI) detects defects like opens/shorts.

3. Lamination

  • Stack-Up: Align inner layers, PP sheets, and outer copper foils per design. Use pins/optical alignment for precision.
  • Pressing: Apply heat (180–220°C) and pressure (1.5–2.5MPa) to melt PP and bond layers. Maintain vacuum to eliminate air bubbles.
  • Post-Press Treatment: Cool boards gradually to avoid warping. Trim edges and remove excess PP.

4. Drilling & Plating

  • Mechanical/Laser Drilling: Drill through-holes, blind/buried vias. Laser drilling is used for microvias (<0.15mm).
  • Deburring: Remove drill swarf and smooth hole walls.
  • PTH (Plated Through-Hole):
  • Desmearing: Clean hole walls with plasma/permanganate.
  • Chemical Deposition: Coat holes with a thin copper layer (1–2ÎŒm).
  • Electroplating: Thicken copper to 20–40ÎŒm for conductivity and durability.

5. Outer Layer Fabrication

  • Dry Film Application: Repeat processes for outer layers.
  • Exposure/Development/Etching: Similar to inner layers but with tighter tolerances.
  • Tin Plating (Optional): Electroplate tin as an etch resist for selective copper retention.

6. Solder Mask & Silkscreen

  • Solder Mask Application: Coat boards with liquid photoimageable solder mask (LPI).
  • Exposure/Development: Expose mask to UV light, leaving pad areas uncovered.
  • Curing: Bake boards to harden the mask.
  • Silkscreen Printing: Add component labels, logos, and markings using UV-curable ink.

7. Surface Finish

  • HASL (Hot Air Solder Leveling): Dip boards in molten solder, then level with hot air. Cost-effective for general use.
  • ENIG (Electroless Nickel/Immersion Gold): Deposit nickel (3–5ÎŒm) and gold (0.05–0.1ÎŒm) for flat surfaces and corrosion resistance.
  • OSP (Organic Solderability Preservative): Apply a thin organic layer for lead-free compatibility.

8. Routing & Testing

  • CNC Routing: Cut boards to final dimensions using milling machines. Add V-scores for easy breaking.
  • Electrical Testing:
  • Flying Probe: Check for opens/shorts with movable probes.
  • Fixture Test: Use bed-of-nails for high-volume inspection.
  • Final Inspection: Visual check for defects (e.g., solder mask bridges, misalignment).

9. Packaging & Shipping

  • Vacuum Packing: Seal boards in anti-static bags with desiccants.
  • Labeling: Include PCB specs, date codes, and compliance marks (RoHS, UL).
How to Make A Copper Metal Core PCB?

Why Choose Best Technology as Metal Core PCB Manufacturer?

  • Global ISO/RoHS/REACH/UL Compliance: One-step certification for EU/US markets.
  • Free DFM Support: Avoid costly redesigns with first-pass success guarantee.
  • 1 Piece MOQ & 24-Hour Rapid Prototyping: Accelerate product validation by 5x, beat competitors to market.
  • A Week Mass Production Turnaround: Eliminate supply chain bottlenecks during peak seasons.
  • Thermal Performance Optimization: Reduce power module temperatures by 25%, extend product lifespan.
  • Strict Quality Inspection: Conduct full inspection in batches and strictly control quality to reduce the cost of rework for customers.
  • Competitive Price: Transparent Price Structure, No hidden Cost to be incurred.
  • Cost-Efficient Material Solutions: Achieve 15% higher profitability for LED/5G products.
  • High-Density Routing Expertise: Miniaturize IoT devices without sacrificing performance.

Welcome to contact us if you have any request for metal core PCB: sales@bestpcbs.com. Looking forward to hearing from you soon!

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2oz Copper PCB for ESDäžšHeavy Copper PCB Manufacturer
Friday, August 1st, 2025

Why choose 2oz Copper PCB for ESD? Let’s discover thickness, current, benefits, ESD protection rules for 2oz Copper PCB.

Are you troubled with these problems?

  • How can PCBs avoid overheating and burnout in high-current scenarios?
  • How can signal stability be ensured in complex environments (high temperature/vibration)?
  • How can heat dissipation efficiency be improved when traditional copper foil is insufficiently thick?

Best Technology’s Services and Solutions

  • 70ÎŒm-400ÎŒm ultra-thick copper layer design directly addresses high-current carrying and heat dissipation issues.
  • Laser etching + electroplating fill-fill process ensures stable high-frequency signal transmission.
  • Customized thermal simulation optimization tailors the design to the end application scenario, extending device life.

Welcome to contact us if you have any request for heavy copper PCB: sales@bestpcbs.com.

What Is 2oz Copper PCB?

A 2oz Copper PCB refers to a printed circuit board with copper traces or planes weighing 2 ounces per square foot (oz/ftÂČ). This equates to approximately 70 micrometers (”m) or 2.8 mils of copper thickness. Such PCBs are designed to handle higher current loads (e.g., 5–10A per trace) with reduced resistance and heat generation compared to thinner copper (e.g., 1oz). They are commonly used in power electronics, automotive systems, and industrial equipment where robust electrical performance and thermal management are critical.

What Is 2oz Copper PCB?

2oz Copper PCB Thickness

A 2oz copper PCB has a copper layer thickness of approximately 70 micrometers (”m) or 2.8 mils, equivalent to 2 ounces per square foot (oz/ftÂČ). This thickness ensures low electrical resistance and efficient heat dissipation, making it ideal for high-current applications like power modules, motor controls, and LED lighting systems.

2oz Copper PCB Thickness

2oz Copper PCB Current

The current capability of a 2oz Copper PCB (70ÎŒm thickness) is approximately 2A per millimeter of trace width for a 10°C temperature rise, doubling the capacity of standard 1oz PCBs. This assumes proper thermal management (e.g., vias, heat sinks) and ambient conditions. Factors like trace length, adjacent heat sources, and insulation layers also influence performance. For precise calculations, use the formula: I = 0.048 × ΔT0.44 × W0.725, where I = current (A), ΔT = temperature rise (°C), and W = trace width (mm).

2oz Copper PCB Current

Why Choose 2oz Copper PCB for ESD?

Reasons why choose 2oz copper PCB for ESD:

  • Lower Resistance, Faster Discharge: Thicker copper (70ÎŒm) reduces trace resistance, enabling rapid conduction of ESD currents to ground and minimizing voltage buildup.
  • Enhanced Grounding Efficiency: Wider traces/planes with 2oz copper provide larger conductive surfaces, optimizing ESD paths and reducing impedance mismatches.
  • Improved Thermal Dissipation: Higher copper mass absorbs and disperses heat generated during ESD events, preventing localized overheating and component stress.
  • Mechanical Robustness: Thicker copper layers resist physical damage (e.g., trace lifting or cracking) caused by sudden ESD-induced current surges.
  • Compliance with ESD Standards: Facilitates meeting IEC 61000-4-2 requirements by ensuring reliable ESD protection in high-risk environments (e.g., consumer electronics, industrial systems).
Why Choose 2oz Copper PCB for ESD?

2 oz vs. 1oz Copper PCB: ESD Performance Comparison

Parameter2oz Copper PCB1oz Copper PCB
Copper Thickness70ÎŒm35ÎŒm
ESD Discharge ResistanceLower (reduced voltage buildup)Higher (risk of voltage spikes)
Thermal CapacityHigher (absorbs/dissipates heat)Lower (risk of thermal stress)
Trace Current Capacity~2A/mm (10°C rise)~1A/mm (10°C rise)
Mechanical DurabilityResists trace lifting/crackingProne to damage under ESD surges
Grounding EfficiencySuperior (low-impedance paths)Moderate (higher inductance)
Compliance (IEC 61000-4-2)Passes 15kV air/8kV contact (Level 4)Struggles at high voltages (risk of failure)
CostHigher (20–40% premium)Lower
Design ComplexityRequires wider traces/viasSimpler for low-power ESD

ESD Protection Rules for 2oz Copper PCB Design

ESD Protection Rules for 2oz Copper PCB Design

  • Grounding Priority: Use full 2oz copper ground planes on inner/outer layers. Connect via stitching vias (≄4 vias/cmÂČ, 0.3mm diameter) to minimize impedance.
  • Trace Design: ESD paths: ≄1.5mm width for 2oz copper. Keep traces <100mm long; route directly to ground.
  • Component Placement: Isolate ESD-sensitive devices (e.g., MOSFETs, CMOS ICs) from edges/connectors by ≄5mm. Shield with 2oz copper guard rings.
  • Protection Devices: Add TVS diodes (≄15kV rating) at I/O ports. Place diodes within 2mm of connectors, using 2oz copper traces for low-inductance paths.
  • Layer Stack-Up: Use 4-layer design: Signal-Ground-Power-Signal. Allocate 2oz copper to ground/power layers for ESD dissipation.
  • Thermal Management: Leverage 2oz copper’s thermal mass to absorb ESD heat. Add thermal vias (0.3mm, 30ÎŒm plating) under hot components.
  • Material & Manufacturing: Specify ESD-safe FR4 (low static generation). Control copper thickness tolerance (±10%) to avoid resistance variability.
  • Testing & Compliance: Validate with IEC 61000-4-2 tests (8kV contact, 15kV air). Use oscilloscopes to verify discharge times <1ns.

Why Choose Best Technology as Heavy Copper PCB Manufacturer?

  • Global Certifications & Compliance – UL, ISO 9001, and IATF 16949 certification for automotive and industrial applications; RoHS and REACH-certified materials for sustainable manufacturing.
  • Competitive Pricing – Cost-effective solutions without compromising quality, optimized for high-volume and low-volume production.
  • Superior Quality Standards – Rigorous adherence to IPC-6012 Class 3 standards for heavy copper PCBs (up to 10oz+).
  • Fast Turnaround – Expedited lead times (as short as 5 days) for bulk orders.
  • Advanced Quality Control – 100% automated optical inspection (AOI) and X-ray testing for defect-free boards.
  • Custom Design Support – Expert engineering assistance for thermal management and high-current trace optimization.
  • Reliable Supply Chain – Stable material sourcing to avoid delays and ensure consistency.
  • One-Stop Solution – From prototyping to mass production, we handle all stages seamlessly.
  • Dedicated Customer Service – 24/7 technical support for real-time project tracking and issue resolution.

Our Heavy Copper PCB Capabilities

Base materialFR4/Aluminum
Copper thickness:4 OZ~10 OZ
Extreme Heavy Copper:20~200 OZ
Outline:Routing, punching, V-Cut
Soldermask:White/Black/Blue/Green/Red Oil
Surface finishing:Immersion Gold, HASL, OSP
Max Panel size:580*480mm(22.8″*18.9″)

How to Get A Quote For Your Heavy Copper PCB Project?

How to Get a Quote for Your Heavy Copper PCB Project

1. Technical Specifications

  • Copper Weight & Layers: Specify the required copper thickness (e.g., 2oz, 3oz, or custom) and the number of layers (e.g., 2-layer, 4-layer, HDI).
  • Board Dimensions: Provide length, width, and thickness (e.g., 100mm × 80mm × 2.0mm).
  • Minimum Trace/Spacing: Define line width and spacing (e.g., 0.1mm/0.1mm for standard heavy copper).
  • Minimum Hole Size: Specify via sizes (e.g., 0.2mm for 2oz copper).

2. Material & Finish Requirements

  • Base Material: Choose between FR4, polyimide, or specialized high-Tg materials.
  • Surface Finish: Select options like ENIG, immersion tin, or HASL.
  • Solder Mask & Silkscreen: Specify colors and types (e.g., green solder mask, white silkscreen).

3. Additional Customizations

  • Impedance Control: Required for high-speed designs.
  • Testing Requirements: Define testing methods (e.g., flying probe, AOI).
  • Special Features: Half holes, blind/buried vias, or rigid-flex designs.

4. Project Logistics

  • Quantity: Total pieces required (e.g., 100 units).
  • Lead Time: Urgency of delivery (e.g., 7–10 days for standard orders).
  • Delivery Address: Ensure accurate shipping details.

Why Choose Best Technology?

  • Precision engineering for high-power applications.
  • Competitive pricing with transparent cost breakdowns.
  • Rapid turnaround and expert technical support.

Submit your detailed requirements today for a quote: sales@bestpcbs.com.

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Consistent Quality Star MCPCB Manufacturer for Prototype
Friday, August 1st, 2025

Star MCPCB is a reliable solution for LED lighting systems that require consistent thermal management and high brightness. When developing LED prototypes, using a well-designed MCPCB star board helps ensure steady performance and longer lifespan. However, finding a dependable supplier for small batches often challenges engineers and buyers alike. At Best Technology, we provide fast, quality service to help customers overcome this issue, improving both inquiry efficiency and product outcomes.

Best Technology is a Chinese Star MCPCB Manufacturer, providing DFM analysis, prototype, fabrication, SMT assembly, and box build service. Rigorous quality control system, rich design and manufacturing experience, sophisticated equipment and technology, quick response, and short lead times really puts a competitive edge to us over the average metal core manufacturers. Our factory supports multiple materials and the customized sizes that meet a variety of LED application needs. Just connect with us at sales@bestpcbs.com for comprehensive solutions.

Consistent Quality Star MCPCB Manufacturer for Prototype

What is a Star MCPCB?

Star MCPCB refers to a metal core PCB shaped like a star or hexagon, typically used in LED lighting. It consists of a copper layer for circuitry, a dielectric for insulation, and a metal base (usually aluminum) for heat dissipation. These boards help LEDs maintain brightness while managing heat effectively. They are small, lightweight, and ideal for use in compact lighting assemblies.

What is a Star MCPCB?

What is the Material of Standard Star MCPCB?

Most standard star MCPCBs use aluminum as the base material because it is both cost-effective and efficient in conducting heat. The circuit layer uses copper, often 1oz or 2oz thickness. Between these layers is a thermally conductive dielectric, which enables fast heat transfer while ensuring insulation. These materials combine to form a durable, high-performance board for LED applications. At Best Technology, we use only RoHS-compliant materials, which are safe and environmentally friendly.

What are the Star MCPCB Dimensions?

Star MCPCB dimensions vary based on LED type and application. Standard sizes include 20mm, 16mm, and 12mm in diameter, with thickness typically around 1.0mm to 1.6mm. Custom shapes and sizes are also available. Our engineers support flexible design options to match specific customer needs. Importantly, tight tolerance is kept to maintain performance and ease of assembly.

How to Do the MCPCB Design?

MCPCB design begins with selecting the proper LED footprint. For star MCPCBs, this often includes layouts for 1W, 3W, or 5W LEDs. Designers need to focus on pad spacing, thermal paths, and hole placement. Clearances should match LED manufacturer guidelines. Best Technology supports customers with DFM (Design for Manufacturing) checks, which help identify design risks before production. This reduces delays and avoids costly revisions.

What Are the Manufacturing Processes of the MCPCB LED Star?

Producing an MCPCB LED star involves several steps:

  1. Copper Clad Laminate Cutting: Sheets are cut to size based on the required star shape.
  2. Drilling: Holes for LED placement or mounting are drilled using precise tools.
  3. Imaging: Circuit patterns are printed using photoresist methods.
  4. Etching: Unwanted copper is removed to form the correct traces.
  5. Dielectric Application: A thermal dielectric is layered for insulation.
  6. Solder Mask and Surface Finish: These protect copper and improve solderability.
  7. Routing and Final Shaping: Boards are cut into star shapes, and edges are cleaned.

Our advanced equipment ensures repeatable, accurate production even for small batches.

What is the Quality Inspection Process During LED Star MCPCB Manufacturing?

Quality is critical. At Best Technology, we perform the following checks during production:

  1. Incoming Material Inspection: All raw materials are verified for conformity.
  2. In-process Checks: Imaging, etching, and drilling are monitored for defects.
  3. AOI (Automated Optical Inspection): Circuit accuracy is checked against design files.
  4. Dielectric Strength Testing: Insulation is tested under voltage to prevent failures.
  5. Final Inspection: Visual and mechanical checks ensure correct dimensions and finish.

Customers often worry about receiving inconsistent quality in prototypes. Our strict process and MES system (Manufacturing Execution System) help maintain traceability and consistency from start to finish.

What Are the Applications of the MCPCB Star Board?

MCPCB star boards are widely used in LED lighting, including:

  • LED flashlights
  • Spotlights
  • Automotive lighting
  • Decorative lighting
  • Medical devices

They support both high and low-power LEDs. Due to the star shape, they are easy to mount onto heat sinks, which helps extend LED life. Our customers in Europe and the US often request customized designs for unique lighting projects, and our fast prototyping service helps them meet tight deadlines.

Where to Get MCPCB Star Board?

Choosing a dependable supplier for MCPCB star boards can greatly improve project outcomes. At Best Technology, we understand the value of both time and budget. That’s why we provide reliable support at every stage—from design to final delivery.

1. Full-Service Support from Start to Finish

  • We assist with design, material selection, and layout optimization.
  • Fast and accurate quotations help you plan your costs easily.
  • Rapid prototyping ensures you meet tight deadlines without stress.

2. Quick and Responsive Communication

  • We reply to all inquiries promptly.
  • Our engineering team offers practical solutions for your specific needs.
  • You will always know the status of your order.

3. Solving Common Customer Pain Points

  • Delay: We shorten lead times with efficient processes.
  • Poor Communication: We keep you informed at every step.
  • Inconsistent Quality: Strict quality checks ensure reliable boards every time.

4. Certified Quality You Can Trust

  • ISO 9001, ISO 13485, IATF 16949, and AS9100D certifications show our commitment to world-class manufacturing.

5. Consistent Quality for Every Order

  • Whether it’s a standard star MCPCB or a custom board, we deliver on time.
  • Quality is consistent, even for low-volume or prototype batches.
Where to Get MCPCB Star Board?

All in all, star MCPCB plays a key role in LED lighting. From efficient heat management to ease of installation, it supports reliable performance in various applications. However, sourcing quality boards quickly remains a challenge. Best Technology helps customers overcome this by offering fast, reliable prototyping and production services. Our team’s experience, combined with strict quality control and responsive communication, helps customers improve project outcomes and reduce risks. Contact Best Technology at sales@bestpcbs.com for better star MCPCB solutions and experience dependable support from design to delivery.

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MCPCB Design, MCPCB Manufacturing Process
Friday, August 1st, 2025

At Best Technology Co., Ltd., we’re experts in MCPCB manufacturing with a complete mcpcb manufacturing process. Our MCPCBs are built to handle tough thermal demands, making them ideal for LED lighting, power converters, automotive modules, and more.

MCPCB Design, MCPCB Manufacturing Process

How to make mcpcb?

Creating an MCPCB isn’t as simple as layering copper and fiberglass. Instead, it starts with selecting the right base, a metal substrate that replaces the usual FR4 core in traditional boards.

This metal core, usually aluminum or copper, becomes the heart of the MCPCB. It supports components, spreads heat, and provides stability. The process then follows with dielectric layering, circuit etching, drilling, and protective coating.

Every layer and every step is essential to maintain heat control, conductivity, and board longevity.

How is a mcpcb manufactured step by step?

Let’s break the process down into clear steps:

Metal Core Preparation

  • A raw aluminum or copper sheet is selected. It’s cleaned and polished to remove oxidation.

Dielectric Layer Application

  • A thermally conductive, electrically insulating layer is laminated onto the metal base. This is the key to heat transfer.

Copper Cladding

  • A thin copper foil is laminated on top of the dielectric. This copper layer will carry the circuit patterns.

Circuit Imaging and Etching

  • Photoresist is applied to the copper surface.
  • UV light exposes the circuit design.
  • Unwanted copper is etched away, revealing the desired pattern.

Drilling

  • Precise holes are drilled for component mounting and vias.

Plating and Solder Mask

  • Copper plating reinforces hole walls.
  • A protective solder mask is applied, ensuring insulation and component alignment.

Surface Finish

  • Finishes like HASL, ENIG, or OSP protect the copper from oxidation and improve solderability.

Testing and Inspection

  • Electrical tests, AOI (Automated Optical Inspection), and final inspections ensure quality.

Each step must be done with care. A slight misalignment can impact performance and reliability.

What materials are used in MCPCB manufacturing?

The choice of materials is what gives MCPCBs their edge.

Metal Core (Base Layer)

  • Usually aluminum for cost-efficiency and solid heat dissipation.
  • Copper is used for high-end applications requiring better conductivity.

Dielectric Layer

  • The thin insulation layer offers high thermal conductivity but must resist high voltages.
  • Common materials include ceramic-filled polymers.
MCPCB Design, MCPCB Manufacturing Process

Copper Layer

  • Carries the electrical signals and forms circuit traces.
  • Thickness varies depending on current-carrying requirements.

Surface Finish

  • Prevents oxidation and ensures strong solder connections.
  • ENIG, HASL, and OSP are common options.

These materials aren’t just chosen for compatibility. Each plays a role in enhancing performance and lifespan.

What is core in manufacturing process?

In the MCPCB world, the core is the metal base. It plays several roles:

  • Heat Dissipation: Pulls heat away from components and spreads it evenly.
  • Mechanical Support: Strengthens the board and reduces vibration risks.
  • Electrical Isolation: Combined with dielectric materials to ensure circuits don’t short.

Unlike FR4 used in standard boards, a metal core makes MCPCBs suitable for high-wattage devices and LEDs.

How is the chipset protected during MCPCB making?

Chipsets are delicate. During manufacturing, every step must protect their integrity.

  • Low Thermal Resistance Layers: These layers keep chipsets cool by drawing heat down quickly.
  • Strong Adhesion: Prevents delamination and cracking under stress.
  • Stable Solder Pads: Ensures chips stay in place during reflow soldering.
  • Controlled Expansion: Metal cores reduce thermal expansion that could otherwise harm chip connections.
MCPCB Design, MCPCB Manufacturing Process

These features not only protect but extend the lifespan of integrated circuits.

What sets MCPCB apart from PCB manufacturing?

While the two may look alike, MCPCB and PCB differ in core design and performance:

  • Thermal Management: MCPCBs are built for heat. Regular PCBs are not.
  • Material Core: FR4 vs. metal (aluminum or copper).
  • Applications: MCPCBs are used in LEDs, power supplies, automotive, and RF circuits. Traditional PCBs serve consumer electronics and low-heat applications.
  • Durability: MCPCBs hold up better in demanding environments.

In short, if your product generates heat, MCPCBs are the smarter choice.

What is the difference between FR4 and Mcpcb?

FR4 is a fiberglass-reinforced epoxy laminate. It’s lightweight, cheap, and widely used. MCPCB, on the other hand, uses a metal core. Here’s the difference:

Thermal Conductivity:

  • FR4: Poor
  • MCPCB: Excellent

Structure:

  • FR4: All dielectric layers
  • MCPCB: Metal core + dielectric + copper

Use Cases:

  • FR4: Phones, computers
  • MCPCB: LEDs, automotive, industrial devices

Durability:

  • MCPCBs are more resistant to mechanical and thermal stress.

How does MCPCB manufacturing improve heat dissipation?

Heat is channeled through the dielectric layer into the metal base. From there, it spreads outward and away from hot spots.

MCPCB Design, MCPCB Manufacturing Process

This design drastically reduces the risk of:

  • Component burnout
  • Solder joint failure
  • Signal degradation

MCPCBs also lower the need for additional cooling solutions like heat sinks or fans. This saves space and cost. This makes them ideal for compact or sealed systems like:

  • LED lighting
  • Automotive sensors
  • Power converters

The key lies in the seamless combination of conductive and insulating materials.

Conclusion:

Understanding the MCPCB manufacturing process will help you understand this product. From chipset protection to thermal performance, it outshines traditional PCBs in demanding applications.

Whether you need reliability, heat control, or performance, MCPCBs are the answer.

Need high-quality MCPCBs with full design and manufacturing support? Best Technology is your trusted partner. Reach out now: Contact us: sales@bestpcbs.com

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What is Difference: Exposed Copper on PCB, Bare Copper PCB?
Friday, August 1st, 2025

Exposed copper on PCB is often seen in circuit designs where certain copper areas are left uncovered. These areas serve specific functions, especially for soldering or electrical connections. Knowing how this differs from a bare copper PCB helps you choose better solutions for your needs.

Best Technology has been manufacturing PCBs and providing PCBA service to a very crowded market for over 19 years. We have a competitive edge in this area through precision processing and the customization capability, our all-process quality control system, as well as through delivery efficiency and the full turnkey EMS PCB service. Our engineering team has rich and valuable experience in optimizing exposed copper on PCB performance, improving the solderability, and the heat dissipation. There is no MOQ limit; you can enjoy the prototype, small quantity trial order, or large volume mass production service. We have the project managers to follow your project. If there is any engineering project, we will give feedback to you to avoid errors and repeated work.

It would be great if you could discuss the exposed copper on PCB requirement in the initial stages of the project, so that we could ensure the optimization from the DFM to the SMT PCBA process. There is 100% appearance checking before shipping, to ensure that there is no oxidation of exposed copper on PCB in your goods batch. Just let us know your exposed copper on PCB requirement, like exposed copper on PCB edge, special pad sizes, and heat dissipation copper surfaces at sales@bestpcbs.com, we will make every effort to meet your any customized exposed copper design requirements.

What is Difference: Exposed Copper on PCB, Bare Copper PCB?

What Does Exposed Copper on PCB Mean?

Exposed copper refers to any area on a printed circuit board (PCB) where the copper surface is not covered by solder mask or surface finish. These areas may include pads, trace edges, or specific zones designed for heat dissipation. Exposed copper is intentionally left uncovered to allow for soldering, electrical connection, or thermal transfer.

To maintain performance and avoid oxidation, these exposed areas are usually protected by a plating layer such as gold (ENIG) or an organic coating like OSP. Without this protection, the copper can easily oxidize, affecting the reliability and lifespan of the PCB.

What Does Exposed Copper on PCB Mean?

What is Copper Pour in PCB?

Copper pour is a design technique where a large area of a PCB is filled with copper. It can help reduce electrical noise, improve thermal management, and support grounding. Sometimes these poured areas are also exposed, depending on the design. Exposed copper pours need a surface finish to prevent oxidation and maintain performance.

What is Difference: Exposed Copper on PCB, Bare Copper PCB?

While both terms seem similar, they have key differences:

  • Exposed copper on PCB means certain parts of the board, like pads or edges, are uncovered for specific use.
  • Bare copper PCB refers to boards without any surface finish. The entire copper area is exposed, with no protection from oxidation or wear.

A board with exposed copper may still have other areas finished with ENIG, HASL, or silver coating. Bare copper PCBs, however, have no such finishes. They are cheaper but require careful handling and storage. In contrast, exposed copper is part of a planned design and used with protective finishes.

What are the PCB Surface Finish Types in Exposed Copper on PCB?

For exposed copper on PCB, surface finishes are used to protect the open copper areas. Each type has specific benefits depending on your application. The most common finishes include:

  • ENIG (Electroless Nickel Immersion Gold): Offers excellent durability and solderability. It protects exposed copper from oxidation and gives a flat surface for fine-pitch components.
  • Immersion Silver: A cost-effective option that works well for high-speed or high-frequency circuits. It provides a smooth surface and reliable performance but requires careful handling to prevent tarnish.
  • HASL (Hot Air Solder Leveling): Widely used and budget-friendly. It coats exposed copper with solder, which protects it and makes soldering easier, though it may not be ideal for very small components.
  • OSP (Organic Solderability Preservative): This eco-friendly coating is used mainly for short-term protection. It is easy to apply and affordable but not suitable for long-term storage.

Choosing the right finish helps you avoid oxidation and supports the function of exposed copper areas. Best Technology provides expert advice on which surface finish matches your product and performance goals.

How to Prevent Oxidation on Exposed Copper on PCB Edge?

The exposed copper on PCB edge is often used for grounding, shielding, or connectors. However, it’s prone to oxidation due to its location. To prevent this:

  • Use ENIG or immersion silver finish on the edge to seal the copper.
  • Store PCBs in dry, anti-static packaging to reduce moisture contact.
  • Apply conformal coating if the edge won’t be soldered, providing extra protection.

Best Technology supports custom edge protection methods to suit different applications, helping you avoid failures caused by corrosion or wear.

ENIG vs Immersion Silver PCB Finish: Which PCB Finish Is Better for Exposed Copper?

When comparing ENIG PCB finish and immersion silver PCB finish, both protect exposed copper but suit different needs:

  • ENIG offers better durability, excellent flatness, and is ideal for complex boards.
  • Immersion silver has lower cost and works well in high-frequency applications, but it needs careful storage to avoid tarnishing.

At Best Technology, we guide customers to choose the right finish for exposed copper areas, ensuring long-term performance and easy assembly.

How to Fix Exposed Copper on PCB?

Fixing exposed copper often depends on whether it’s intentional or a result of damage. If it’s unintentional, here’s what you can do:

  • Apply a solder mask or conformal coating to cover the copper.
  • For critical areas, add a surface finish like ENIG or HASL.
  • In repair cases, use solder to reflow and seal the copper trace or pad.

To avoid these issues, work with trusted manufacturers. Best Technology ensures all exposed copper areas are well-finished or protected, based on your specifications.

How to Fix Exposed Copper on PCB?

What’s the Pros and Cons of Exposed Copper on PCB?

Pros:

  • Allows easy soldering for components and connectors.
  • Supports grounding and thermal management.
  • Useful for test points and current paths.

Cons:

  • Risk of oxidation without surface finish.
  • Needs careful handling during assembly and storage.

With expert support, the benefits outweigh the risks. Best Technology applies the right surface finish to every exposed copper section, ensuring reliable results for your product.

Why Work with Best Technology for Exposed Copper Solution?

Many customers worry about exposed copper causing failures due to oxidation or poor soldering. Others face delays, low communication, or inconsistent quality from suppliers. At Best Technology, we solve these problems with:

  • A professional engineering team who understands your design and guides finish selection.
  • Strict quality control to ensure every board meets your needs.
  • Fast response times, full traceability, and clear communication throughout production.

We provide a smooth experience, reduce risks, and help you deliver high-quality products to your market quickly. Contact Best Technology at sales@bestpcbs.com for reliable PCB solutions and support for exposed copper designs.

Ultimately, exposed copper on PCB plays a vital role in modern circuit design. Whether used for soldering, grounding, or heat dissipation, these uncovered copper areas must be protected to maintain performance and prevent oxidation. Knowing the difference between exposed copper and bare copper PCBs, along with the right surface finish options like ENIG or immersion silver, helps ensure better product quality and reliability. Any technical problem or any PCB inquiry, just call us at +86-755-2909-1601 or at sales@bestpcbs.com.

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Aluminium PCB manufacturing process, PCB assembly factory
Friday, August 1st, 2025

As a professional aluminum PCB manufacturer, Best Technology delivers reliable, cost-effective solutions with a complete in-house aluminium PCB manufacturing process—from raw material sourcing to final assembly.

How is aluminium PCB made?

Unlike standard FR4 boards, aluminium boards require special materials, customized layering, and high-precision etching to perform reliably under high temperatures.

It begins with a base of aluminium, selected for its thermal conductivity and strength. This base acts as the backbone of the entire structure. Over this, a dielectric layer is added—a thermally conductive yet electrically insulating material. This layer allows heat to pass through to the metal core without shorting the circuit.

Next comes the copper foil. This conductive layer is laminated onto the dielectric using heat and pressure. Once bonded, the copper is patterned using photolithography. Then, etching forms the conductive tracks that carry current across the board.

Finally, the surface is coated with a protective solder mask. The board is drilled, tested, and cut into its final shape, ready for assembly. Every step is controlled to ensure high precision and reliability.

What are the raw materials for aluminum manufacturing?

For aluminium PCBs. The base material is an aluminium alloy, often 5052 or 6061, known for corrosion resistance and good mechanical performance. These alloys are lightweight yet robust, ideal for handling mechanical stress and thermal loads.

Next is the dielectric layer. Typically made of epoxy resin or a ceramic-filled polymer, this layer must be thermally efficient. The goal is to transfer heat quickly without compromising electrical insulation.

The conductive layer is pure copper, usually between 1oz and 3oz thick. This copper sheet is what gets etched to form the traces. To finish, a solder mask is applied to protect the copper and prevent short circuits.

Each material plays a crucial role. Choosing the right combination impacts performance, durability, and cost. That’s why experienced manufacturers like Best Technology take material quality and testing very seriously.

What are the layers of aluminum PCB?

Unlike traditional PCBs, these boards typically have three core layers:

  • Copper Layer: It’s where all the routing happens. The thickness varies based on current load, usually between 35ÎŒm and 105ÎŒm.
  • Dielectric Layer: It insulates the circuit while transferring heat to the metal base. Its thickness affects thermal resistance.
  • Aluminium Base Layer: This bottom layer supports the entire board. It also acts as a heat sink, dissipating excess energy and maintaining stable temperatures.

What are the manufacturing processes for Aluminium?

The aluminium PCB manufacturing process differs slightly from FR4, due to the metal base and heat-sensitive applications.

  • Material Preparation: Aluminium base sheets are cleaned and coated with the dielectric layer.
  • Copper Lamination: A copper foil is bonded using thermal pressure.
  • Image Transfer: Photolithographic techniques are used to apply the circuit pattern.
  • Etching: Unwanted copper is removed, leaving the circuit traces.
  • Drilling: Holes are drilled for vias and mounting points.
  • Plating: If needed, through-holes are plated for multi-layer connectivity.
  • Solder Mask Application: A protective coating is applied to prevent oxidation.
  • Silkscreen Printing: Labels, logos, and identifiers are printed.
  • Surface Finish: ENIG, HASL, or OSP finishes are applied based on customer needs.
  • Final Testing: Each board is electrically tested for continuity and shorts.
  • Routing and Packaging: Boards are cut, inspected, and packed for delivery.

Every step must meet tight tolerances. Even minor defects can affect performance, especially in LED, automotive, and power systems.

What are the pros and cons of aluminum PCB?

Aluminium PCBs have their strengths—and a few limitations.

Pros:

  • Superior Heat Dissipation: Aluminium spreads heat fast. This reduces hotspots and extends component life.
  • High Mechanical Strength: These boards are robust, reducing the risk of cracks and warping.
  • Lightweight Yet Durable: Aluminium provides rigidity without the weight of steel or ceramic.
  • Cost-Effective: Compared to ceramic substrates, aluminium PCBs are more affordable for high-performance needs.
  • Eco-Friendly: Aluminium is recyclable, making it a greener choice.

Cons:

  • Limited Flexibility: Aluminium is rigid. It’s not suitable for flexible PCB applications.
  • Single-Sided Complexity: Most aluminium PCBs are single-layered. Multi-layer designs are possible but more complex and costly.
  • Processing Requirements: Special tools are needed for drilling and etching, raising initial setup costs.

Still, the benefits far outweigh the downsides in most high-power applications. That’s why aluminium boards dominate industries like LED, power electronics, and automotive lighting.

How thick is aluminum PCB?

Thickness matters. It affects strength, heat transfer, and overall reliability.

For aluminium PCBs, the metal base typically ranges from 0.8mm to 3.2mm. The most common thickness is 1.6mm, offering a good balance between strength and heat dissipation. Some high-power applications may use up to 5mm for extra thermal control.

Thickness also depends on the product’s end use. For compact devices like LED bulbs, thinner substrates are preferred. For industrial use, thicker bases ensure long-term performance under heavy loads.

What is the thermal resistance of aluminum PCB?

Thermal resistance is crucial. It determines the heat dissipation performance of the PCB board. The lower the thermal resistance, the better the heat transfer effect, which is one of the advantages of aluminum PCB boards.

A typical aluminium PCB has a thermal resistance between 0.3°C/W and 1.0°C/W. The exact value depends on the dielectric material and its thickness.

The dielectric is designed to transfer heat quickly from the copper layer to the metal base. This lowers component temperature, improves performance, and extends lifespan.

How thick is the dielectric layer of aluminum PCB?

The dielectric layer not only ensures the passage of heat, but also acts as an insulator. The thickness of the dielectric layer directly affects the insulation performance and thermal resistance.

Most dielectric layers are between 50ÎŒm and 150ÎŒm thick. Thinner layers offer better heat transfer but may reduce electrical insulation. Thicker layers improve isolation but limit thermal performance.

Choosing the right thickness is about balance. It depends on voltage requirements, power density, and end-use environment.

How do aluminium PCBs work?

Aluminium PCBs work by balancing three critical needs: electrical conduction, mechanical support, and heat dissipation. They combine a conductive copper layer with a heat-spreading aluminium base, connected by a special dielectric.

When current flows through the copper traces, it generates heat. The dielectric layer moves this heat down to the aluminium base, which then spreads it across the board and out to the environment. This keeps components cool, even under heavy load.

When to use aluminum PCB?

Aluminum PCBs are widely used in applications where heat is an issue. That includes:

  • LED Lighting: Heat control improves brightness, lifespan, and efficiency.
  • Power Supplies: High-current paths stay cool and stable.
  • Automotive Electronics: High vibration resistance is perfect for engine bays and dashboards.
  • Communication Equipment: Enhanced thermal management ensures signal reliability.
  • Industrial Controllers: Strong mechanical support reduces failure under stress.

If your design involves high-power components or tight thermal tolerances, aluminium PCBs are the solution.

Conclusion:

Aluminum substrates have good thermal conductivity, mechanical strength and cost-effectiveness. Whether you’re building LED lights, industrial controls, or automotive systems, aluminium PCBs provide a solid foundation. Their superior heat management protects components, improves efficiency, and extends service life.

If you’re ready to upgrade your design with dependable aluminium PCBs, our experts at Best Technology are here to help. With advanced equipment, experienced engineers, and quick turnaround, we deliver quality you can trust. Contact us now at sales@bestpcbs.com

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