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Direct Thermal Path Copper PCB Manufacturer
Wednesday, June 4th, 2025

What Is Direct Thermal Path Copper PCB?

A Direct Thermal Path Copper PCB, also called DTP copper PCB or sinkpad copper base PCB. It is a type of high-performance circuit board used in applications where heat dissipation is critical. Unlike standard printed circuit boards (PCBs), which rely on dielectric layers to insulate the copper circuitry from the metal base, a DTP PCB removes this insulation layer directly beneath the heat-generating components. This creates a direct connection between the component, the copper layer, and the copper base.

This structure allows heat to flow quickly and efficiently away from the source, reducing thermal resistance and improving the performance and reliability of electronic components, especially in high-power or high-current environments. These boards are widely used in LED lighting, automotive systems, telecom infrastructure, and power electronics.

Direct Thermal Path Copper PCB Manufacturer

Why Thermal Management Matters in Electronics?

Every electronic device generates heat when it’s running. While small gadgets like phones may only get warm, high-power devices like industrial lighting systems or motor controllers can heat up rapidly. If this heat isn’t removed effectively, it can cause serious problems:

  • Component failure
  • Reduced lifespan of electronic parts
  • Malfunction due to overheating
  • Safety risks, especially in automotive or aerospace applications

To prevent these outcomes, thermal management becomes a critical aspect of PCB design. Engineers use a combination of heat sinks, thermal vias, and copper planes—but in extreme conditions, these are often not enough. That’s where DTP copper PCBs come in—they allow maximum heat transfer from hot components to the surrounding environment, helping electronics run cooler and more reliably.

Features of DTP Copper PCB

Direct thermal path copper PCBs stand out due to their special construction and capabilities. Here are some of their key features:

  • Thick copper base (up to 10 oz or more): Helps carry more current and draw heat away quickly.
  • Direct contact between copper circuit and metal base: Eliminates the thermal barrier of dielectric materials.
  • Excellent heat dissipation: Thermal resistance is significantly lower compared to regular MCPCBs.
  • Strong mechanical structure: Supports heavy components without deformation or cracking.
  • Stable performance in harsh environments: Suitable for high-temperature, vibration, and high-voltage conditions.

These features make DTP PCBs a practical choice for demanding applications where standard PCBs would overheat or fail.

How Does DTP PCB Work?

The principle behind a DTP PCB is simple: remove the thermal barrier (dielectric layer) between the heat source and the metal base. In a typical metal core PCB, the heat generated by a component passes through a dielectric layer (which is an electrical insulator) before reaching the metal base. This dielectric slows down the heat transfer.

In a DTP PCB, the designer removes the dielectric material under the power component and creates a direct copper pad that touches the metal base directly. This structure dramatically reduces thermal resistance and allows heat to flow out much faster.

In short, DTP PCBs give heat a shortcut—a direct path to escape—leading to lower operating temperatures and better performance.

How Does the Convexity Pad Create?

The convexity pad is a small bump or raised copper structure that connects the top copper circuitry directly to the metal base below. This feature is critical in DTP PCBs because it serves as the contact point for heat transfer. Actually, the convexity pad is a little complicated than normal. Normally the thickness of copper core/substrate is 0.8mm, 1.0mm, 1.2mm, 1.4mm, 1.6mm, 2.0mm. And there’re blue protection film on both sides. We will remove that protection film after raw material cutting, before convexity making, so that copper can be etched. After that, we will grind the copper core to make sure it’ll be clear enough, so that in next step another film can be added to make trace.

Then, we will add one extra layer of film (normally blue color, and will refer to blue film hereafter) on whole area copper core, and after developing & etching, only selected area of blue film will be kept and other area will be removed away. In fact, the area of blue film will be the place convexity will be.

Direct Thermal Path Copper PCB Manufacturer

Why Aluminum Base Is Not Suitable to Make DTP PCB?

As we know, the convexity pad directly connects the copper base serving as the substrate to the thermal pads of the LED without any insulating thermal conductive material in between. In this way, the heat from the LED can be directly transferred to the copper substrate of the base through the solder, without having to pass through the electrical traces on the base surface and the insulating materials for heat transfer. This is why DTP PCB also is called thermoelectric isolation as well. (The heat output path of the LED is directly connected to the copper plate and separated from the electrical traces). As for why aluminum substrates cannot be used, it is because the heat pads of the led chips need to be directly soldered to the copper substrate through the solder on the reserved protrusion on the base, and aluminum doesn’t bond well with standard solder materials.

In addition to this, some manufacturers said they can make DTP aluminum PCB. Maybe they indeed made it, but need to spend a lot of time and the cost is much higher than DTP copper base PCB. And compared with copper base PCB, the thermal conductivity of aluminum PCB is slightly lower, so we always not recommend customers to make DTP aluminum PCB.

Considerations While Using Direct Thermal Path MCPCB

Before incorporating DTP copper PCBs into your design, keep these factors in mind:

1. Component Placement

Ensure components that generate high heat are directly above the DTP pads. Misalignment can compromise thermal efficiency.

2. Base Thickness

The thickness of the copper base affects both heat transfer and mechanical strength. Heavier bases improve heat conduction but may reduce flexibility.

3. Thermal Simulation

Use thermal analysis software to simulate heat dissipation before production. This helps identify hotspots and optimize layout.

4. Dielectric Material

Where dielectric is still used, choose materials with high thermal conductivity (such as ceramic-filled polymers).

5. Mounting & Enclosure

DTP PCBs perform best when mounted to a heatsink or metal enclosure. Make sure there’s good thermal interface material between them.

6. Surface Finish

Use finishes like ENIG (Electroless Nickel Immersion Gold) or OSP (Organic Solderability Preservative) to improve soldering and surface protection.

Direct Thermal Path Copper PCB Manufacturer

DTP Copper PCB Manufacturing Process

Manufacturing a direct thermal path copper PCB requires careful attention and precision. Here’s a step-by-step breakdown:

Step 1: Base Metal Selection

A thick copper base (typically 1.6–3.2 mm) is chosen as the base layer. This base serves as the thermal sink for the entire board.

Step 2: Lamination

A high-thermal conductivity dielectric is laminated to the copper base. This is done only where insulation is needed.

Step 3: Circuit Layer Preparation

A copper foil (typically 1–3 oz) is applied on top. The PCB manufacturer then performs photolithography and etching to define the circuit pattern.

Step 4: Dielectric Removal

The dielectric under high-heat components is selectively milled or punched to expose the copper base.

Step 5: Convex Pad Formation

Using precision CNC machining, a raised copper pad is formed on the exposed area. This pad directly contacts the component’s thermal pad.

Step 6: Surface Finishing

The board receives a protective finish like ENIG, OSP, or immersion silver to prevent oxidation and improve solderability.

Step 7: Solder Mask and Silkscreen

Solder mask is applied to protect the circuitry, followed by silkscreen for labeling.

Step 8: Testing and Quality Control

Each board undergoes electrical and thermal testing to ensure performance, conductivity, and durability.

This manufacturing process results in a high-performance PCB that can handle extreme heat conditions with ease.

Common Applications of DTP MCPCB

Because of their outstanding heat management, DTP copper PCBs are widely used across industries that rely on high-power or high-brightness components. Here are some key applications:

  • Automotive LED lighting: Headlights, brake lights, and DRLs require efficient thermal dissipation to maintain brightness and longevity.
  • Power electronics: DTP PCBs are used in DC/DC converters, motor controllers, and battery management systems for better heat control.
  • Industrial lighting: High bay and floodlights benefit from improved thermal design to prevent premature failure.
  • Telecommunication systems: Base stations and network equipment use DTP PCBs to manage heat from amplifiers and processors.
  • Aerospace and defense: Systems in satellites and aircraft need PCBs that perform reliably under thermal and environmental stress.

Wherever performance and reliability are non-negotiable, DTP copper PCBs are a trusted solution.

FAQs About Direct Thermal Path MCPCB

Q1. What makes DTP PCBs different from regular MCPCBs?

The key difference is the removal of the dielectric layer beneath the component, enabling direct heat flow from the copper pad to the metal base. This dramatically improves thermal conductivity.

Q2. Can DTP copper PCBs be used in multilayer stackups?

Typically, they are single-sided. However, hybrid multilayer configurations are possible for complex applications, though they require advanced design and manufacturing techniques.

Q3. Is copper the only metal used for DTP base material?

In high-end applications, copper is the preferred base due to its superior conductivity and durability. Aluminum is cheaper but less effective in DTP designs.

Q4. Do I still need a heatsink with a DTP PCB?

Yes, in most cases. While the DTP board efficiently moves heat to its base, the heat still needs to exit the board—often through a heatsink or the product’s metal housing.

Q5. How can I get a DTP copper PCB made?

You’ll need a PCB manufacturer like Best Technology that specializes in metal core PCBs and has equipment for precision CNC milling and selective dielectric removal. Request thermal simulation support for best results.

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Posted in best pcb, bestpcb, Design Guide, FAQ, mcpcb, Metal Core PCB, SinkPAD | No Comments »

Multilayer PCB Design Guide, Multilayer PCB Stack-up
Friday, May 30th, 2025

Multilayer PCB design is at the heart of compact, high-speed electronics. As more devices require higher functionality in smaller packages, multilayer PCBs have become the go-to solution. In this blog, we’ll explore how these boards are designed, what materials go into them, and how they are manufactured.

Best Technology is a trusted PCB manufacturer based in China, specializing in small to medium-volume PCB fabrication, PCB assembly, and comprehensive electronic manufacturing services (EMS). As a one-stop PCB solutions provider, we go beyond manufacturing. Our services cover turnkey assembly, component sourcing, box build assembly, PCBA testing, and full electronics assembly. Whether you’re developing a prototype or scaling up to full production, Best Technology is committed to delivering reliable quality, fast turnaround, and personalized support to meet all your PCB and electronics manufacturing needs.

What Is PCB Multilayer?

A multilayer PCB is a type of printed circuit board made by stacking multiple copper layers with insulating materials in between. While a single-sided PCB has only one conductive layer and a double-sided PCB has two, a multilayer PCB typically starts at four layers and can exceed thirty layers depending on the design complexity.

These copper layers are interconnected using vias (small plated holes). The main advantage is that multilayer PCBs allow more complex circuitry in a compact form. They’re used when simple routing becomes impossible due to high component density, high-speed signals, or design restrictions.

Multilayer boards usually contain signal layers, power planes, and ground planes that are symmetrically arranged to ensure electrical balance and mechanical stability.

Multilayer PCB Design Guide, Multilayer PCB Stack-up

Advantages of Multilayer PCB

There are many advantages of multilayer PCBs, especially for high-end, compact, and performance-driven applications:

  • High Circuit Density: Multilayer PCBs offer more real estate by using multiple layers. This helps route more connections without crowding.
  • Compact Size: By stacking layers, complex circuits can be condensed into smaller board sizes, which is important for modern gadgets.
  • Better Signal Integrity: Ground and power planes shield signal layers, helping reduce electromagnetic interference and signal loss.
  • Enhanced Reliability: Since many connections are internal and automated, multilayer PCBs tend to be more reliable than manually wired boards.
  • Improved Power Distribution: Dedicated power planes help distribute power evenly across the board.
  • Cost Efficiency in Mass Production: Although more expensive to design, they become cost-effective when produced at scale.

What Materials Are Used for Multilayer PCB?

Multilayer PCB construction involves several materials chosen based on the application’s electrical, thermal, and mechanical requirements. Common materials include:

  • Copper Foil: Used for all conductive layers. Thickness ranges from 0.5oz to 3oz, depending on current requirements.
  • Core Material (FR4): The most widely used substrate, made from fiberglass-reinforced epoxy. It provides mechanical strength and insulation.
  • Prepreg (Pre-impregnated resin): A resin-impregnated fiberglass that bonds layers together during lamination.
  • High-Frequency Materials: For applications like 5G or RF circuits, materials such as PTFE, Rogers, or ceramic substrates are used.
  • Solder Mask: This green or colored coating protects the board from oxidation and solder bridges.
  • Silkscreen: Printed on the board to mark component positions and labels.

For high-temperature or high-reliability applications, alternative materials like polyimide or metal cores may also be used.

Why Are There No 3 Layer PCBs?

Technically, you can make a 3-layer PCB, but they are very uncommon and often impractical. PCB manufacturing is designed to favor even-numbered layer configurations for several reasons:

1. Symmetry: Even-layered stack-ups offer better mechanical balance. Odd layers may lead to board warping due to uneven internal stress.

2. Manufacturing Simplicity: Most production lines are optimized for 4, 6, or 8 layers. A 3-layer board would require a custom process, which increases cost.

3. Signal Performance: High-speed signals benefit from a symmetrical structure. Odd-layer designs make it harder to maintain signal and power integrity.

Because of these reasons, designers usually move to 4-layer designs when they outgrow double-sided layouts.

How to Design a Multilayer PCB?

Designing a multilayer PCB starts with understanding the functional needs of your product. Here’s a step-by-step process:

  • Define Layer Count: Decide how many layers are required based on circuit complexity, signal integrity, and available space. Common configurations include 4, 6, and 8 layers.
  • Create a Stack-Up: Plan how each layer will function — signal, ground, or power. Layer arrangement impacts EMI performance and routing efficiency.
  • Component Placement: Place high-speed, sensitive, and power components with care. Keep analog and digital sections separate.
  • Routing Strategy: Route critical signals on inner layers to shield them from external noise. Use short, direct routes for clock and high-speed lines.
  • Via Planning: Use through-hole vias, blind vias, and buried vias to connect different layers.
  • Impedance Control: For high-speed signals, calculate and control the trace impedance using PCB design software.
  • Thermal Management: Add thermal vias and consider copper pour for better heat distribution.
  • Design for Manufacturability (DFM): Ensure trace widths, spacing, hole sizes, and clearances follow manufacturer guidelines.

Design tools like Altium Designer, Eagle, or KiCad can help streamline multilayer PCB design while checking for errors along the way.

How to Build a Multilayer PCB Stack-Up?

A stack-up is the arrangement of copper and dielectric layers in a multilayer PCB. It affects signal quality, EMI, thermal behavior, and mechanical strength.

Multilayer PCB Design Guide, Multilayer PCB Stack-up

Common 4-Layer Stack-Up:

  • Top layer: Signal
  • Inner layer 1: Ground
  • Inner layer 2: Power
  • Bottom layer: Signal

6-Layer Stack-Up Example:

  • Top: Signal
  • Layer 2: Ground
  • Layer 3: Signal
  • Layer 4: Signal
  • Layer 5: Power
  • Bottom: Signal

Tips for Effective Stack-Up:

  • Keep ground and power layers close for decoupling.
  • Place critical signals between ground planes.
  • Symmetry reduces warping.
  • Maintain consistent dielectric thickness to control impedance.

At Best Technology, our engineering team assists clients with stack-up planning to match their performance, size, and cost targets.

Multilayer PCB Manufacturing Process

The multilayer PCB manufacturing process involves combining multiple copper and insulation layers through precise steps:

1. Inner Layer Imaging

    Each internal copper layer is printed with the desired circuit pattern using photoresist and UV light.

    2. Etching

    Unwanted copper is chemically etched away, leaving only the circuit traces.

    3. Lamination

    All layers are stacked with prepreg between them and laminated under high heat and pressure to form a single board.

    4. Drilling

    Holes are drilled through the stack to connect layers. These include through-hole, blind, and buried vias.

    5. Plating

    Copper is plated into drilled holes and on the board’s surface to create electrical paths.

    6. Outer Layer Imaging and Etching

    Outer layers undergo the same photoimaging and etching process as inner layers.

    7. Solder Mask and Silkscreen Application

    A solder mask is added to prevent oxidation and short circuits. Silkscreen is printed for component labeling.

    8. Surface Finishing

    Finishes like HASL, ENIG, or OSP are applied to pads for better solderability.

    9. Testing and Inspection

    Every board undergoes electrical tests and visual inspections to catch defects.

    At Best Technology, we combine automated optical inspection (AOI), flying probe testing, and impedance measurement tools to ensure product quality at every stage.

    Multilayer PCB Application

    Multilayer PCBs are used in products where performance and miniaturization are critical. Here are some typical multilayer PCB applications:

    • Smartphones and Tablets: Compact devices need high-density PCBs to fit advanced features in tight spaces.
    • Medical Equipment: Imaging machines, heart monitors, and portable diagnostic tools depend on stable multilayer circuits.
    • Automotive Electronics: Modern vehicles use multilayer PCBs for infotainment systems, sensors, and control units.
    • Telecommunication Devices: Routers, switches, and 5G antennas rely on multilayer designs for signal integrity.
    • Industrial Controls: Multilayer PCBs support automation equipment and high-voltage circuits.
    • Military and Aerospace: Satellites, drones, and radar systems require rugged multilayer boards with excellent thermal and electrical performance.

    How to Identify Multilayer PCB?

    Identifying a multilayer PCB can be tricky just by looking at the surface. However, here are some tips:

    • Edge View: Under a magnifier, you can often see multiple stacked layers at the board edge.
    • X-ray Inspection: In factories, X-ray equipment can show internal connections and vias not visible from outside.
    • Blind/Buried Vias: If the board has vias that don’t go through the entire thickness, it’s likely multilayer.
    • Complexity and Component Density: A compact board handling many components usually suggests a multilayer design.
    Multilayer PCB Design Guide, Multilayer PCB Stack-up

    FAQs

    1. What is the typical number of layers in a multilayer PCB?

    Most commonly, multilayer PCBs have 4, 6, or 8 layers. High-end designs may go up to 32 or more.

    2. Can multilayer PCBs be flexible?

    Yes. Flexible multilayer PCBs are used in wearables, cameras, and aerospace applications where bending is needed.

    3. Are multilayer PCBs expensive?

    They cost more than single or double-layer PCBs but offer more value in space savings and performance.

    4. What’s the difference between blind and buried vias?

    Blind vias connect outer and inner layers. Buried vias connect internal layers only, and are hidden from the surface.

    5. How does Best Technology support multilayer PCB projects?

    We offer complete support — design review, stack-up suggestions, high-speed materials, and full traceability via MES systems.

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    Posted in best pcb, bestpcb, Design Guide, FAQ, PCB News | No Comments »

    Is Thicker Copper PCB Always Better? How to Choose Suitable Copper Thickness?
    Monday, May 26th, 2025

    In high-power electronics, thermal management is everything. Whether you’re designing LED modules, motor controllers, or power converters, one of the first decisions you’ll make is selecting the right copper thickness for your copper core PCB.

    It’s tempting to assume that more copper is always better. After all, thicker copper offers lower resistance and better heat conduction. But here’s the truth: while thicker copper can enhance performance, it also introduces new challenges—in cost, manufacturability, and even thermal efficiency in certain contexts.

    In this article, we’ll dive into how copper thickness affects heat dissipation, mechanical integrity, and overall PCB performance. You’ll also learn how to find the sweet spot—balancing copper thickness with practical requirements.

    How to Choose Suitable Copper Thickness?

    What Does Copper Thickness Really Do in a PCB?

    Copper thickness in a PCB is typically measured in ounces (oz), where 1 oz equates to approximately 35 micrometers of thickness. The thicker the copper, the more current it can carry and the more heat it can dissipate—up to a point.

    For example:

    • 1 oz copper is standard in many applications like consumer electronics or low-power LED boards.
    • 2 oz–3 oz copper is often used in medium- to high-power applications, such as telecom equipment or automotive control modules.
    • 4 oz–6 oz copper or more is reserved for ultra-high-current or extreme thermal environments, like industrial drives or inverters.

    In a copper core PCB, the copper layer not only serves as a trace but also acts as a heat conduit. But simply adding more copper isn’t always the best strategy—it needs to be balanced with mechanical, thermal, and design constraints.

    How to Choose Suitable Copper Thickness?

    How Does Thicker Copper Affect Thermal Conductivity?

    Thermal conductivity is the rate at which heat passes through a material. Copper’s thermal conductivity is excellent—about 398 W/m·K—much higher than FR4 (0.25 W/m·K) or aluminum (205 W/m·K). Thermal conductivity improves as copper gets thicker—up to a point.

    • A 1 oz (35”m) copper layer offers good heat flow for standard loads.
    • 2 oz (70”m) or 3 oz (105”m) copper layers are used for medium-to-high power circuits.
    • Ultra-thick copper like 6 oz (210”m) or more is suitable for extreme applications like power inverters or motor drivers.

    But while thicker copper improves thermal conductivity, it also increases thermal mass, which can slow down heat transfer in fast-cycling circuits. That means copper core PCBs with ultra-thick copper aren’t always the most efficient in dynamic thermal environments.

    What Happens to Mechanical Strength as Copper Gets Thicker?

    A copper core PCB with heavy copper also becomes more rigid. This can be beneficial in harsh environments (e.g. EV chargers, industrial robots) where vibration or mechanical shock is a concern.

    However, ultra-thick copper comes with drawbacks:

    • Reduced flexibility: Too much copper can crack during mechanical stress.
    • Higher internal stress: Thicker copper can warp other layers if not carefully designed.
    • Drilling and routing challenges: High copper thickness limits hole aspect ratio and increases the risk of burrs or tool breakage.

    In short, thicker copper increases strength but decreases the PCB’s resilience during assembly or use.

    Manufacturing Challenges of Thick Copper Core PCBs

    As copper thickness increases, so does the cost—not just of materials, but also in processing:

    • Etching Control: The deeper the copper, the harder it is to maintain precise trace widths and spacing. Over-etching or under-etching can occur, especially with high-aspect-ratio designs.
    • Drilling Difficulties: Thick copper increases drill wear and may require specialized bits. This adds time and cost.
    • Solder Mask Issues: Solder mask adhesion becomes less reliable with thick copper due to surface tension and lack of anchor points.
    • Fine-pitch traces are harder to produce with heavy copper.

    A copper core PCB with 3 oz copper may cost up to 1.8x more than a standard 1 oz version. And a 6 oz copper design might require specialized etching equipment, which not all PCB manufacturers can support. That’s why working with an experienced supplier like Best Technology is crucial.

    How to Choose the Right Copper Thickness for Your PCB?

    Rather than defaulting to the thickest copper available, consider these design factors:

    • Power Dissipation

    Estimate total wattage and heat output. Use simulation tools or thermal imaging to understand hot zones.

    • Current Capacity

    Follow IPC-2152 guidelines to determine trace width vs. amp load. For example:

    1 oz copper: ~10A for 100 mil trace (surface)

    2 oz copper: ~18A for same width

    • Board Size and Layer Count

    Larger boards may use thinner copper with thermal vias and heat sinks. Multilayer designs must balance all layers.

    • Application Environment

    Will the board be exposed to vibration, moisture, or rapid temperature swings? If yes, go thicker and stronger.

    • Budget and Lead Time

    Thick copper PCBs cost more and take longer to fabricate. Optimize design for performance within your price range.

    Rule of thumb:

    • Use 1 oz–2 oz copper for LED lighting, chargers, and automotive control boards.
    • Go for 3 oz–4 oz only if you have continuous high current or extreme heat.
    • Consider 5 oz+ only for industrial power systems or heavy-duty applications.

    Case Study: How Thicker Copper Solved and Created Problems

    A client building a 500W motor driver switched from 2 oz to 5 oz copper core PCB to improve thermal dissipation. While heat decreased by 12%, they faced new issues:

    • Via drilling became inconsistent due to copper pull-out.
    • Board warpage increased after reflow soldering.
    • Assembly cost rose by 30%.

    We helped them optimize with a hybrid solution:

    • Kept 2 oz on signal layers.
    • Added localized copper in power zones.
    • Improved base layer contact for better heat flow.

    Finally, thermal performance remained strong, but manufacturability and cost were brought back under control.

    How to Choose Suitable Copper Thickness?

    Conclusion

    When designing a copper core PCB, it’s easy to fall into the trap of thinking “thicker is better.” In reality, optimal performance comes from careful engineering—not just stacking on copper.

    At Best Technology, we help clients worldwide balance copper thickness with thermal, mechanical, and manufacturing constraints. We use simulation, prototype validation, and DFM support to ensure your final product is both high-performing and cost-effective.

    Why Work With Best Technology for Copper Core PCBs?

    We are not just PCB fabricators—we are problem solvers. Our copper core PCB services include:

    ✔️ Copper thickness options from 1 oz to 10 oz

    ✔️ Full-stack DFM analysis and thermal modeling

    ✔️ IPC-compliant thermal and electrical simulations

    ✔️ MES-based quality traceability

    ✔️ Rapid prototyping and scalable mass production

    We help you avoid over-designing or under-designing copper thickness—saving cost and ensuring long-term reliability. No matter the application—EVs, LEDs, telecom, or industrial—you’ll find the right copper balance with us.

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    FAQs

    Q1: Is 3 oz copper enough for a 100W LED module?

    Yes, in most cases 3 oz copper on a properly designed copper core PCB can handle that heat load efficiently.

    Q2: How does copper thickness affect signal integrity?

    Thicker copper affects impedance. It must be calculated carefully for high-speed or RF circuits.

    Q3: Can thick copper cause warping during reflow?

    Yes. Uneven copper thickness across layers can cause thermal imbalance. This must be addressed in stack-up design.

    Q4: What’s better: thicker copper or more thermal vias?

    Depends. Thermal vias can be more efficient in some layouts and cost less than increasing copper.

    Q5: Does Best Technology support custom stack-ups for copper PCBs?

    Absolutely. We provide custom stack-up planning based on your power, thermal, and mechanical needs.

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    Custom PCB Sinkpad for High-power LED Solutions
    Friday, May 23rd, 2025

    High-power LED applications come with a serious challenge: heat. When LEDs generate too much heat and it’s not properly managed, it can shorten the life of the light, affect its brightness, or even cause total failure. That’s where SinkPAD PCBs come in. Unlike regular MCPCBs, a SinkPAD PCB offers a direct thermal path that transfers heat away from the LED quickly and effectively. If you’re working with powerful LEDs, custom SinkPAD PCBs can make a big difference. At Best Technology, we specialize in custom SinkPAD solutions designed for maximum heat dissipation and long-term reliability.

    What is a SinkPAD PCB and How Does it Work?

    A SinkPAD PCB is a type of metal core PCB designed specifically for high-thermal performance. The term “SinkPAD” refers to a patented technology where the thermal pad of the LED is directly connected to the metal base of the PCB, creating an uninterrupted thermal path. In traditional MCPCBs, a dielectric layer sits between the copper circuit layer and the metal base, reducing thermal conductivity. But in a SinkPAD design, that barrier is removed or minimized in the area under the LED, allowing heat to flow directly to the metal core and then to the heatsink.

    Custom PCB Sinkpad for High-power LED Solutions

    Why is Thermal Management So Critical in High-Power LED Applications?

    LEDs are efficient, but they’re not immune to heat. In fact, around 70%–85% of the electrical energy in an LED is converted into heat. If that heat isn’t quickly removed, it can cause several issues:

    • Decreased light output (lumen depreciation)
    • Color shifting over time
    • Shorter lifespan
    • Component failure in extreme cases

    Good thermal management maintains LED brightness, performance, and stability. For high-power LEDs, such as those used in automotive headlights or industrial lighting, standard cooling methods often fall short. That’s why advanced thermal solutions like custom SinkPAD PCBs are essential — they offer superior heat dissipation to keep your LEDs working reliably.

    What are the Advantages of Custom SinkPAD PCBs for LED Projects?

    Choosing a custom SinkPAD PCB means tailoring the thermal design to fit your exact LED setup. Here are the key benefits:

    • Better heat dissipation: The direct thermal path lowers the junction temperature, which helps maintain brightness and prevent overheating.
    • Compact design: You can eliminate bulky heatsinks, which saves space in your lighting product.
    • Improved reliability: Lower operating temperatures lead to fewer failures and longer LED lifespan.
    • Higher power density: You can run brighter or more LEDs in a small area without worrying about thermal overload.
    • Consistent performance: No hotspots or uneven heat spread — just stable and predictable operation.

    A custom SinkPAD solution allows you to match the board layout, materials, and thickness exactly to your LED requirements, which is especially helpful for complex or high-end lighting systems.

    Custom PCB Sinkpad for High-power LED Solutions

    What Materials are used in SinkPAD LED PCBs?

    The choice of materials is crucial for any high-performance PCB, especially one handling thermal management. In SinkPAD PCBs, the most common materials include:

    • Aluminum base: Widely used due to its cost-effectiveness and good thermal conductivity. Suitable for medium-power LED applications.
    • Copper base: Offers superior heat conductivity compared to aluminum and is typically used in ultra-high-power or demanding environments.
    • High-thermal conductivity dielectric (if used): In areas not using the exposed metal pad, a thin dielectric layer may still be present. The goal is to keep thermal resistance as low as possible.

    At Best Technology, we work with both aluminum and copper bases and can advise on the best choice depending on your heat requirements and budget.

    How is a SinkPAD PCB Manufactured?

    The SinkPAD PCB manufacturing process requires high precision and special techniques to expose the thermal pad directly to the metal base. Here’s how it typically works:

    1. Material preparation: Selection of copper or aluminum core with appropriate thickness.
    2. Drilling and routing: Laser or mechanical drilling is used to create openings that allow the thermal pad to contact the base metal directly.
    3. Etching and circuit formation: Copper traces are etched for the electrical circuit.
    4. Thermal pad exposure: Dielectric material is selectively removed from under the LED thermal pad area.
    5. Plating and finishing: Surface finishes like ENIG or OSP are applied to the copper pads.
    6. Testing and inspection: Thermal and electrical tests ensure the board performs as intended.

    This process allows the heat from the LED to travel through the exposed pad directly into the metal base, rather than relying on thermal via stacking or thick dielectric layers.

    Where are SinkPAD PCBs Used in Real Applications?

    SinkPAD PCBs are used in any application where high power and reliable thermal control are required. Here are some real-world examples:

    • Automotive headlights and fog lamps: Require compact designs and powerful light with efficient heat dissipation.
    • Industrial floodlights: Often run for long hours and need stable performance under high thermal stress.
    • Medical lighting: Such as surgical lights that demand high brightness and zero failure during operation.
    • UV curing systems: Used in printing and adhesives, which generate intense heat.
    • Stage or studio lighting: Where color consistency and brightness are key, and high-powered LEDs are standard.

    These applications benefit from the direct thermal pathway offered by SinkPAD PCBs, ensuring the LEDs can operate at full brightness for long periods without failure.

    Design Considerations of SinkPAD PCB in LED Lighting Devices

    When designing a SinkPAD PCB for LED lighting, it’s not just about efficient heat dissipation — it’s about optimizing performance, reliability, and manufacturability. Here are the key factors to consider:

    1. LED Thermal Pad Alignment

    Ensure the thermal pad of the LED package aligns precisely with the exposed metal area of the SinkPAD. Any misalignment can increase thermal resistance and reduce heat transfer efficiency.

    2. Base Metal Selection

    Aluminum is cost-effective and sufficient for many applications, but copper is preferable for ultra-high-power LEDs due to its superior thermal conductivity. Choose the base metal based on your LED’s power output and operating environment.

    3. Board Thickness

    The thickness of the metal core affects both heat spreading and mechanical strength. Thicker cores (e.g., 2.0mm copper or aluminum) can handle more heat but may increase the overall weight and cost.

    4. Dielectric Isolation (If Applicable)

    In areas that don’t require direct heat transfer, a thin dielectric layer may still be used. Select materials with high thermal conductivity (>1.0 W/m·K) and low thermal resistance to maintain performance.

    5. Surface Finish

    For high-reliability soldering and corrosion resistance, finishes like ENIG (Electroless Nickel Immersion Gold) or OSP (Organic Solderability Preservative) are commonly used. Choose a finish compatible with your LED’s soldering profile.

    6. Component Layout and Spacing

    Leave enough space between LEDs and other heat-sensitive components. This helps prevent local hotspots and ensures even heat distribution across the board.

    How Does Best Technology Serve You for Custom SinkPAD PCBs?

    Choosing the right SinkPAD PCB partner is as important as the design itself. Here’s how Best Technology supports you at every step:

    • Advanced thermal engineering support
    • Material flexibility including copper and aluminum
    • Custom layout design
    • Certified quality system
    • Full traceability
    • Fast quoting and prototyping

    With over a decade of experience in custom thermal PCB design, Best Technology is your reliable partner for SinkPAD LED solutions.

    FAQs

    1. What’s the difference between SinkPAD and standard MCPCBs?

    Standard MCPCBs use a dielectric layer between the LED and the metal core, while SinkPAD removes that layer under the thermal pad for direct heat transfer.

    2. Can SinkPAD PCBs handle very high-wattage LEDs like 10W or 50W?

    Yes. SinkPAD PCBs are specifically designed for high-wattage LEDs where rapid and efficient heat dissipation is critical.

    3. Is copper better than aluminum for SinkPAD PCBs?

    Copper offers better thermal conductivity than aluminum, but it’s also more expensive. The choice depends on your application and thermal budget.

    4. Are SinkPAD PCBs only used for LED lighting?

    While they’re most commonly used in LED applications, they can be used in any high-power electronics needing excellent thermal control.

    5. How can I get a quote for a custom SinkPAD PCB?

    Simply send us your Gerber files and project details. Our engineering and sales team will respond with a tailored solution and quotation within 24 hours.

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    Posted in best pcb, bestpcb, Design Guide, FAQ, mcpcb, Metal Core PCB, SinkPAD | No Comments »

    Mobile Phone PCB Prototype, Mobile Circuit Boards Manufacturer
    Monday, April 28th, 2025

    Have you ever wondered what powers your mobile phone behind the screen? Every tap, swipe, or call you make is possible because of one hidden hero: the mobile phone PCB. In simple terms, the mobile circuit board connects and controls all parts of your phone. It links the battery, screen, camera, processor, and even your wireless network. Without it, nothing would work.

    At Best Technology, we design and manufacture custom mobile PCBs that support today’s advanced smartphones. As a leading mobile PCB manufacturer both in China and Vietnam, we have decades years of experience in producing high-quality boards for mobile devices, wearables, and smart electronics. Certificated by ISO9001, IATF16949, ISO13485, AS9100D, it shows we have enough capability to produce highest quality mobile PCB board. Whether you need flexible, rigid, HDI, RF or multilayer PCBs, we deliver one-stop solutions with fast turnaround and competitive pricing.

    Mobile Phone PCB Prototype, Mobile Circuit Boards Manufacturer

    What Is a Mobile Phone PCB?

    A mobile phone PCB is the core of your smartphone, which drives your phone be intelligent. It looks like a green or black plate populated with many small electronic parts. These components are connected through thin copper lines etched onto the board. Together, they power your phone and make sure each part works smoothly.

    In smartphones, the PCB board mobile phone is usually a multi-layer board, meaning it has several layers stacked together. This design helps save space and supports high-speed data processing. The PCB also holds all essential parts like the processor, memory, charging port, and wireless chips.

    What Does a Mobile Phone PCB Actually Do?

    A mobile phone PCB acts like the brain and nervous system, it mainly used to connect and manage every part of the phone, its working principle is:

    • Power distribution: It sends power from the battery to other parts.
    • Signal transmission: It lets the processor talk to the screen, camera, and sensors.
    • Component support: It holds everything in place and keeps them working together.

    Without the mobile phone PCB, the battery wouldn’t know how to charge, the screen wouldn’t respond, and the speaker wouldn’t play music. It handles all the behind-the-scenes activity while you use your apps and make calls.

    Mobile Phone PCB Prototype, Mobile Circuit Boards Manufacturer

    Core Components on a Mobile Phone PCB

    A mobile phone PCB always is a populated PCB. At the top of the PCB, you’ll find the antenna point, where the antenna connects. Your phone connects to Wi-Fi, Bluetooth, and cellular networks through these antennas. Each component on the PCB plays its unique role:

    • Antenna Switch: A 16-leg switch that controls signal direction. Sometimes built together with the PFO.
    • PFO (Power Frequency Oscillator): Manages signal frequency. Found next to the antenna switch.
    • Network IC: Controls mobile network functions. In some phones, it’s built into the CPU.
    • Power IC: Found near brown capacitors. Regulates power across the PCB.
    • CPU (Processor): The largest IC. Handles all system commands and performance tasks. Some phones have two CPUs.
    • Flash IC: Stores system data and software. Located beside the CPU.
    • Logic IC: A 20-pin chip. Manages basic logic operations.
    • Charging IC: Found beside R22. Controls battery charging.
    • Audio IC: Controls sound functions. Placed close to the Power IC.
    • Capacitors: Store and release electrical energy. Help stabilize power supply.
    • Resistors: Control the flow of current. Protect other parts from too much power.
    • Diodes: Allow current to flow in one direction only. Prevent power damage and signal errors.

    Below is a multi-layer PCB used in iphone. These parts make it possible for you to browse, take photos, and connect with the world.

    Mobile Phone PCB Prototype, Mobile Circuit Boards Manufacturer

    Why Multi-layer PCBs Are Standard in Smartphones?

    Today’s smartphones are like mini computers. They handle everything from streaming video to running powerful apps. To keep up, mobile phone PCB design has evolved. One of the biggest upgrades? The switch to multi-layer PCBs. Here we listing main advantages of using multi-layer PCBs in mobile phone.

    Firstly, multi-layer PCBs offer higher circuit density, allowing more components like processors and memory to fit in the limited space. For example, the iPhone 14 Pro uses a 10-layer PCB to deliver powerful functionality in a compact design.

    Secondly, they improve high-speed signal transmission by reducing interference through ground and shielding layers, ensuring stable and fast data transfer—a must for modern smartphones.

    Additionally, multi-layer PCBs reduce the size and weight of smartphones. By accommodating more circuits in the same area, they help achieve smaller, lighter designs, like in the Apple Watch Series 8.

    Finally, multi-layer PCBs enhance reliability and mechanical strength. Their complex construction improves durability and vibration resistance, ensuring a longer-lasting product.

    How Inner and Outer Layers Interact in a Mobile PCB Stack?

    In a mobile PCB board, the inner and outer layers work together like a team. The outer layers handle the connection of chips, antennas, and components you can see. Meanwhile, the inner layers manage signal traces, power distribution, and ground planes.

    Signals often travel between these layers through vias—small holes filled with metal that link one layer to another. This allows for faster, cleaner communication between the mobile PCB components, such as the CPU, RAM, and radio circuits.

    Mobile Phone PCB Prototype, Mobile Circuit Boards Manufacturer

    Materials Used in Mobile PCB Board

    Choosing the right materials is crucial in mobile phone PCB manufacturing. Each layer and part of the board serves a different purpose, so engineers carefully select materials to match performance needs, durability, and size constraints. Here’s a comparison of commonly used mobile PCB materials:

    MaterialDescriptionProsCommon Use in Mobile PCB
    FR4Fiberglass-reinforced epoxy laminateCost-effective, stable electrical propertiesBase material in most mobile PCB cores
    PolyimideFlexible and heat-resistant materialGreat for flexible PCBs and foldable applicationsUsed in camera modules, folding phones
    RogersHigh-frequency laminateLow dielectric loss, excellent RF performanceAntenna sections, 5G, Wi-Fi, Bluetooth
    Teflon (PTFE)Non-stick, high-performance polymerUltra-low signal loss, ideal for high-speed signalsUsed in high-speed communication layers
    CeramicAdvanced inorganic compositeExcellent heat dissipation, high frequency stabilityPower modules, 5G RF front-end, shielding

    PCB Layout Basics for Mobile Phones

    A solid layout is the backbone of any mobile phone PCB. Designers start with the schematic, which maps every component and connection. Mobile PCB layout focuses on a few key goals:

    • Short signal paths to avoid delay.
    • Clear power and ground planes for stability.
    • Thermal zones to manage heat.
    • Shielded areas for RF sections like Wi-Fi and GSM modules.
    • Placing the processor, RAM, power management ICs, and antennas carefully prevents problems later.

    Warm tips:

    Keep power and ground layers as solid planes. Avoid breaks or thin sections, which create voltage drops. Also, decoupling capacitors should sit close to power pins of chips.

    Tips for GSM, Wi-Fi, Bluetooth, and 5G Mobile PCB Antennas

    1. Keep antennas away from metal—metal blocks signals.
    2. Use ground clearance around antenna traces to reduce noise.
    3. Match impedance of the RF trace to avoid reflection.
    4. Add shielding near high-speed digital lines to prevent signal loss.

    For 5G, which uses millimeter-wave bands, the routing must be super precise. Even a few millimeters can affect signal strength. Tools like electromagnetic simulation software help refine these paths.

    How AI and Automation Are Changing PCB Layout?

    AI and automation have brought big changes to mobile PCB design in this two year. Instead of placing parts manually, designers can now rely on smart layout tools that optimize paths automatically. Machine learning predicts optimal routing paths. Automation assists in component placement, thermal analysis, and EMI reduction. They suggest better placements in seconds—saving hours of work.

    AI also speeds up mobile PCB testing. It spots defects on boards using image recognition. That means more accurate inspections, less rework, and faster production.

    As AI tools improve, they’ll continue to reduce errors, cut costs, and deliver better mobile board designs. It’s a leap forward for the industry.

    What Does Best Technology Serve You?

    At Best Technology, we provide complete solutions for mobile PCB design and manufacturing. Whether you’re developing a new smartphone, tablet, or wearable device, we help you build it from the ground up. Our services including but not limited to:

    • Custom mobile phone PCB layout and design based on your needs
    • Single-layer to 32+ layer boards, including HDI, rigid-flex, and high-frequency options
    • Advanced material selection such as FR4, polyimide, Rogers, and BT epoxy
    • Rapid prototyping and small-volume production with quick delivery
    • Full testing services like AOI, flying probe, impedance, and X-ray inspection

    With over 18 years in the PCB industry, we’ve supported top-tier brands in building reliable, high-performance mobile electronics. Our team works closely with customers and give the best suggestions to optimize your mobile circuit board design. If you are interested in the mobile PCB develop, you are welcome to contact our team at sales@bestpcbs.com.

    FAQs

    1. What does a mobile phone PCB diagram show?

    It shows where each component is placed on the board and how they are connected through copper traces.

    2. How can I avoid power issues in PCB layout?

    Use ground planes, short power paths, and place capacitors close to chips for voltage stability.

    3. How do I identify damaged parts on a mobile PCB?

    Use thermal cameras, multimeters, and reference schematics to locate shorted, burned, or faulty components.

    4. What makes Best Technology a strong mobile PCB manufacturer?

    They provide full-stack design-to-production all in one service, expert engineering support, DFM check, SI, PI analysis and a proven track record in mobile electronics.

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    Posted in best pcb, bestpcb, Design Guide, FAQ, FR4 PCB, PCB News, PCB Technology | No Comments »

    Copper Metal Core PCB​, Copper Core PCB Factories​ & Manufacturer​
    Thursday, April 24th, 2025

    Copper Core Metal Core PCB Definition

    A copper metal core PCB is a circuit board that using a copper substrate as its base. Unlike standard FR4 boards, it offers better thermal conductivity and enable to manage high temperatures in demanding electronics. It is primarily used in LED lighting, power electronics, and automotive systems. The copper base improves heat dissipation and reduces thermal stress on components.

    In these PCBs, copper doesn’t just act as a trace layer. It becomes the core, ensuring mechanical strength and thermal stability. The copper layer can range in thickness based on heat dissipation needs.

    Copper Metal Core PCB​, Copper Core PCB Factories​ & Manufacturer​

    Copper Core PCB Structure

    The structure of a copper core PCB includes three key layers:

    Copper base layer – This is the thick metal sheet at the bottom, used to transfer heat efficiently.

    Dielectric layer – This insulating layer sits between the copper base and the circuit layer. It ensures electrical isolation while allowing heat to pass through.

    Circuit layer – This is the top layer where traces and components are mounted. It’s usually made of copper foil, etched to form the required circuit paths.

    Copper Core PCB Structure

    If it is a double-sided copper core PCB, then the copper core located at the center, and bottom layers is the same as top layer – dielectric layer and copper trace layer.

    Types of Copper Core PCB

    Copper core PCB can be divided into two different types, the normal copper PCB and sinkpad copper PCB.

    • Normal Copper Core PCB

    This is the most basic version. The structure of normal copper PCB is the same as aluminum core PCB. It consists of the standard three layers mentioned above. It’s simple, effective, and often used in applications where heat needs to be controlled but not aggressively dissipated.

    • SinkPad Copper-Based PCB

    The sinkpad copper PCB also called thermoelectric separation copper-based PCB. This type of PCB offers more advanced thermal management, up to 400W/m.k. It has a sinkpad we called convexity, which creates a direct thermal path from the heat source (like an LED chip) to the copper core. It removes the barrier between the heat source and the copper base, dramatically improving heat transfer. These boards are often found in high-performance LED lighting, power modules, and heavy-duty electronics.

    SinkPad Copper-Based PCB

    Sinkpad copper-based pcb stack up:

    Sinkpad copper-based pcb stack up

    Features of Copper Core PCB

    • Superior heat dissipation than aluminum PCB, thermal conductivity up to 400W/m.k.
    • Stable dimensional, resistant to bending, warping, or mechanical stress.
    • Extend the lifespan of components by keeping temperatures low and stable
    • Reliable heat transfer, vital for LEDs, power amplifiers, and high-voltage devices.
    • High durability under harsh conditions
    • Stable electrical performance

    Copper Metal Core PCB Design Guidelines

    1. Identify heat-generating components early like LED chips and position them close to the copper base or over thermal vias. This way, heat can flow downward into the copper core instead of building up on the surface.

    2. The thickness of the copper core can vary from 0.5mm to 3.2mm or even more. Thicker cores handle more heat but also make the board heavier and harder to machine. Choose a thickness that fits your heat dissipation needs without over-engineering the design.

    3. If you’re creating a multi-layer board with copper core, make sure your layer stack-up supports signal integrity and EMI shielding. Keep high-speed signals away from noisy power planes and include ground layers where needed.

    4. Put heat-sensitive parts like sensors, microcontrollers, or delicate analog chips far from high-power elements like MOSFETs or power LEDs.

    5. Copper is harder than aluminum or FR4. Make sure your PCB manufacturer is equipped to handle precise drilling and milling of copper-based substrates without damaging the boards.

    6. Before finalizing the design, use simulation tools to predict how heat will spread across the board.

    Copper Metal Core PCB Applications

    • High power LED (up to 200W)
    • Automotive electronics like power control modules, headlight systems, and battery management
    • DC-DC converters, MOSFET drivers, motor controllers
    • Drives, inverters, and heavy machinery
    • Telecommunication systems
    • Medical devices – In imaging and surgical tools

    How to Choose Copper Core PCB Factories?

    Not all copper core PCB factories are the same. Here’s what to look for:

    • Experience – Look for manufacturers with years in metal-core PCB production.
    • Material sourcing – Ask where they get their copper and dielectric materials.
    • Precision capabilities – Can they handle tight tolerances and advanced designs?
    • Thermal testing – Make sure they offer in-house thermal testing or simulation.
    • Customization – They should be able to tweak thickness, layers, or designs as needed.
    • Certifications – ISO9001, UL, and RoHS are a good start.

    A good partner won’t just make your board—they’ll improve your product.

    Top 10 Copper Core PCB Manufacturers (In No Particular Order)

    When it comes to sourcing high-quality copper core PCBs, choosing the right manufacturer is crucial for ensuring thermal efficiency and long-term reliability. Here are ten trusted names in the industry, known for their expertise in copper metal core PCB production:

    1. Adwin Circuits

    Looking for something highly customized? Adwin Circuits is a solid choice if your project needs detailed attention. They’re known for working closely with customers to get everything just right, especially on the thermal side.

    2. PCBgogo

    Need your boards fast and don’t want to break the bank? PCBgogo is super popular for a reason. They’re fast, affordable, and make it easy to order online—even for copper core options.

    3. Millennium Circuits Limited (MCL)

    Based in the U.S., MCL focuses on high-quality builds with short lead times. If you’ve got a tight deadline and still want top-notch results, they’re definitely worth considering.

    4. Best Technology

    With over 18 years in the industry, Best Technology really knows their stuff when it comes to metal core and copper-based PCBs or sinkpad PCB. They handle everything—from design advice to assembly—and specialize in custom builds for demanding applications like LED lighting and power electronics. As an expert, they know what you want and make it into reality.

    5. PCBWay

    If you’ve ever ordered a PCB online, chances are you’ve heard of PCBWay. They make the whole process super smooth and have a good track record for copper metal core PCBs too. Great support and flexible pricing make them a go-to for hobbyists and professionals alike.

    6. Sierra Circuits

    These folks are based in California and have a strong reputation in industries like aerospace and medical tech. If you need a copper core board that meets tight specs or certifications, Sierra’s a good fit.

    7. JLCPCB

    One of the biggest names in online PCB manufacturing, JLCPCB is known for rock-bottom prices and quick delivery. Their copper core options are great for early prototyping and scaling up later.

    8. FX PCB

    FX PCB is another good option if your project needs serious thermal management—especially in LED lighting or high-power circuits. They’re all about balancing price and performance.

    9. PCBONLINE

    This one’s a full-service provider, so if you need a one-stop-shop—from bare board to final assembly—they’ve got you covered. Their copper core offerings are strong, and they’ve got solid quality control in place too.

    10. Leiton GmbH

    If you’re based in Europe or need a manufacturing partner closer to home, Leiton GmbH is a solid German company. They’re known for attention to detail and reliable builds, especially for industrial applications.

    Why Choose Best Technology as Your Copper Core PCB Supplier?

    Best Technology offers a full-service experience for all copper PCB needs.

    Copper Metal Core PCB Prototype

    Quick-turn copper metal core PCB prototypes are available for engineers looking to validate thermal designs. Prototyping services include design feedback, material consulting, and fast delivery, even for complex builds.

    Copper Metal Core PCB Assembly

    Complete copper metal core PCB assembly is available in-house. From surface mount to through-hole soldering, every board is built to exact specifications. Inspection services like AOI, X-ray, and functional testing guarantee reliability.

    FAQs

    1. What is the advantage of using a copper core PCB over an aluminum core PCB?

    Copper conducts heat better than aluminum. It also supports higher mechanical strength and is suitable for high-performance applications.

    2. Can copper core PCBs support multilayer designs?

    Yes. Copper core boards can be designed as multilayer PCBs. They often include signal, ground, and power planes with efficient heat sinking.

    3. What is the typical copper thickness for these boards?

    Copper base thickness ranges from 0.5mm to 3.2mm. Circuit layers usually vary between 1oz and 6oz depending on current load.

    4. Are copper metal core PCBs expensive?

    Yes, they cost more than FR4 boards due to material and process complexity. However, they reduce cooling costs and extend device life, offering long-term value.

    5. How can I request a quote from a copper core PCB manufacturer?

    Send your Gerber files, BOM list, and specifications to the manufacturer. Then our sales will provide pricing based on volume, complexity, and delivery timelines.

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    Posted in best pcb, bestpcb, Design Guide, FAQ, mcpcb, Metal Core PCB, SinkPAD | No Comments »

    Custom LED PCB, LED PCB Manufacturer
    Thursday, April 24th, 2025

    In the rapidly evolving world of electronics and lighting, the demand for custom LED PCB is climbing fast. Whether you’re building industrial lights, consumer gadgets, or smart wearables, choosing a dependable LED PCB manufacturer can set your project apart in terms of quality, efficiency, and performance.

    If you’re looking for high-performance lighting solutions with reliable circuitry, you need more than just a product. You need a trusted partner. Best Technology is that partner. We are a leading LED PCB manufacturer with over 18 years of hands-on experience. We specialize in crafting custom LED PCB solutions that go beyond ordinary lighting components. Our team supports industries ranging from automotive and aerospace to medical and consumer electronics. Whether you need a DIY LED PCB board, SMD LED PCB board, or help with LED PCB board replacement, we offer unmatched quality, guidance, and long-term value.

    What Is a Custom LED PCB?

    What is a custom LED PCB? A custom LED PCB is a printed circuit board designed to support and connect light-emitting diodes in a specific configuration. Unlike off-the-shelf boards, these are tailored to fit your product’s shape, power needs, and environmental demands.

    Whether it’s a curved light strip, a compact torch design, or a large-format display backlight, a custom LED PCB meets your unique criteria with pinpoint accuracy. It’s not just about making it fit—it’s about optimizing performance.

    Custom LED PCB, LED PCB Manufacturer
    Custom LED PCB, LED PCB Manufacturer

    Why Customization Matters in LED PCB Design?

    Every application has different priorities. Some need intense brightness. Others demand heat control in confined spaces. A few require flexible materials or rigid aluminum cores. A standard LED PCB board simply can’t’ cater to all these needs.

    With custom LED PCB design, you have full control over:

    • LED type and layout
    • Trace width and thickness
    • Copper weight
    • Heat dissipation paths
    • Voltage and current specifications
    • Mounting hole placements
    • Base material selection

    What Services Does Best Technology Offer?

    At Best Technology, we’ve been making LED PCBs for decades. We offer full support—from idea to finished board. Whether you need 1 piece for testing or 10,000 pieces for production, we’ve got you covered.

    We manufacture:

    • Aluminum LED PCBs: Great for heat control
    • FR4 LED PCBs: Good for low-power applications
    • Ceramic LED PCBs: Perfect for small, hot environments
    • Copper-based PCBs: Excellent for high current
    Custom LED PCB, LED PCB Manufacturer

    We also provide:

    • Free DFM checks (design for manufacturing)
    • Quick samples (5–7 days turnaround)
    • Full testing (visual, electrical, thermal)
    • Component sourcing and assembly

    Our team understands both electronics and lighting design, so your custom LED PCB will meet your real-world needs.

    Our LED PCB Capabilities

    ItemCapabilities
    Layer Count1 – 10 Layers
    Max Board Dimension24*64″(610*1625mm)
    Min Board Thickness0.6mm
    Max Board Thickness4.0mm
    Conductor Thickness0.5oz – 10oz
    Min Line Width/Line Space4/4mil (0.10/0.10mm)
    Min Hole Diameter10mil (0.25mm)
    Min Punch Hole Dia0.12″ (3.0mm)
    Min Hole Spacing16mil (0.4mm)
    Min PAD Ring(Single)3mil (0.075mm)
    PTH Wall ThicknessNormal: 0.59mil (15um); HDI: 0.48mil (12um)
    Min Solder PAD Dia14mil (0.35mm)
    Min Soldermask Bridge8mil (0.20mm)
    Min BAG PAD Margin5mil (0.125mm)
    PTH/NPTH Dia TolerancePTH: ±3 mil (0.075mm); NPTH: ±2mil (0.05mm)
    Hole Position Deviation±3mil (0.075mm)
    Outline ToleranceCNC: ±6 mil (0.15mm); Die Punch: ±6 mil (0.1mm)
    Max Aspect Ratio10:01
    Surface TreatmentENIG, ENEPIG, HAL, HASL(LF), OSP, Tin Imm

    Popular Applications of Custom LED PCBs

    • Street Lighting
    • Automotive Interiors and Headlights
    • Backlighting for Displays
    • Architectural and Accent Lighting
    • Medical Imaging Devices
    • Consumer Electronics
    • Agricultural Grow Lights

    Different environments need different board types. For example, a grow light needs stable, long-term brightness, while a car brake light needs to handle vibration and heat.

    How to Design a DIY LED PCB Board?

    Designing your own LED PCB can be a fun and educational project. Here’s how to get started:

    1. Pick your LED type: Decide how bright you want the light to be. Choose between small SMD LEDs or larger high-power ones.

    2. Use design software: Free tools like EasyEDA or KiCad help you draw your circuit layout.

    3. Decide on materials: If your LEDs will get hot, choose aluminum or copper as the base (though ceramic substrate has excellent thermal dissipation, but it is very expensive compared with aluminum or copper).

    4. Draw your layout: Make sure LED placement is even. Place current paths (traces) wide enough to handle the power.

    5. Add resistors: These control how much current goes through each LED.

    6. Test your layout: Before making the board, simulate the circuit using the design software.

    7. Order a prototype: Send your design to a PCB maker for a test run.

    Tip: Always check the polarity of your LEDs before soldering—they only work one way!

    What’s Inside an LED Circuit Board Diagram?

    An LED circuit diagram shows how the board works. It’s like a map for your board.

    You’ll see:

    • LEDs (usually marked with a triangle and line)
    • Power input (VCC) and ground (GND)
    • Resistors (to control current)
    • Drivers or ICs (for smart control, if used)

    Here is a typical led circuit board diagram example:

    LED Circuit Board Diagram

    How to Choose the Right Base Material for Your LED PCB?

    Choose the right material can help you save much time and money to revise or update the design. Nowadays, there are 5 types of base materials will be used in LED PCB design, each has unique properties and applications.

    • Aluminum: Best for cooling and cost-effective. Used in most LED lights.
    • FR4 (fiberglass): Cheap and easy to use. Works well for low-power lights.
    • Ceramic (AlN or BeO): Great at handling heat. Used in medical or high-precision tools. It always used in high-end applications, like aerospace or military.
    • Copper: Good conductor. Useful when you need a lot of power in a small space. But it has heavier weight among all materials.
    • Polyimide: Flexible material, always used in flexible devices.

    Tip: If your LED gets warm to the touch, go with aluminum or copper. If it stays cool, FR4 is usually fine.

    Key Considerations for LED PCB Strip Design

    1. Current and voltage rating:

    LED strips typically operate at standard voltages like 12V or 24V DC. Choosing the right voltage ensures consistent brightness and prevents overheating. For instance, a 24V strip loses less power over long runs compared to a 12V one—voltage drop is approximately 4–6% lower over a 5-meter run.

    2. Copper thickness:

    Standard copper thickness is 1oz, which is suitable for low-power strips. For high-current applications like industrial lighting, go for 2oz or more.

    3. LED layout and spacing:

    Spacing affects light uniformity and heat distribution. For example:

    • 60 LEDs/m offers a soft glow suitable for accent lighting.
    • 120 LEDs/m or higher gives a brighter, more uniform output, ideal for task lighting.

    4. Solder mask color:

    White and black solder mask are popular in led lighting design. White solder masks are preferred for LED strips because they reflect up to 80–90% of visible light, improving luminous efficiency. Black masks, on the other hand, absorb more heat and can reduce light output by up to 20% in reflective applications.

    5. Thermal vias:

    If you’re using a multi-layer PCB, thermal vias help transfer heat from the surface layer to the internal layers or to the aluminum base.

    Whether you’re working on decorative lighting or industrial-grade illumination, these choices make a visible difference.

    Common Mistakes to Avoid in LED PCB Board Replacement

    Replacing an LED PCB board may seem simple, but several mistakes can lead to costly repairs or system failure. Here are a few things to watch out for:

    1. Not matching the voltage and current ratings:

    2. Poor heat management:

    3. Wrong LED type or color temperature:

    4. Using the wrong connectors or soldering techniques:

    5. Skipping testing after installation:

    Best Technology offers replacement services and supports compatibility checks to avoid costly errors.

    How to Get a Quote for a Custom LED PCB?

    Getting a quote for a custom LED PCB is simple if you prepare the all information. Most of manufacturers are happy if you can provide following files in the quote phase.

    1. Gerber files and BOM

    2. Detailed Specifications:

    • PCB size and shape
    • Number of layers
    • Copper thickness
    • Base material (e.g., aluminum, FR4)
    • Solder mask color
    • Surface finish (ENIG, HASL, etc.)

    3. LED details: mention the LED type, power rating, quantity, and placement.

    4. Order quantity and lead time: higher volumes usually mean lower cost per unit. Also, let the supplier know if you need it urgently.

    5. Special requirements: if you need waterproofing, specific connectors, or certifications (RoHS, UL, etc.) or IPC class III, include those details too.

    If you have this information already, reach out Best Technology, and our sales team will review your files and send a best quotation within 12 hours.

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    Posted in best pcb, bestpcb, Design Guide, FAQ, mcpcb, Metal Core PCB | No Comments »

    Via Filling the Circuit Board Technique for PCB Fabrication
    Wednesday, April 23rd, 2025

    When high-density designs and tight tolerances become the norm, via filling steps in as a reliable technique to elevate performance and reliability. Used in multilayer and HDI PCBs, via filling ensures smooth connections, supports stacked vias, and improves soldering quality.

    At Best Technology, we have over 18 years of experience manufacturing advanced PCBs with various via-filling techniques. From BGA designs to microwave circuits, our team supports every step with precision and care. Our factory provides conductive and non-conductive via filling, backed by strict quality inspection and cost-effective solutions. If you’re looking for expert help in via-filled circuit boards, you’re in the right place.

    What Is Via Filling in Circuit Boards?

    Via filling is a process of inserting a special material into drilled holes (vias) in a PCB layer. These holes, which typically connect one layer to another, are filled with conductive or non-conductive compounds depending on the design. The goal is to create a sealed, flat surface, improve strength, and allow for finer components on the surface—especially important when vias are under BGA or QFN pads.

    Via Filling the Circuit Board Technique for PCB Fabrication

    What Is the Purpose of Via Filling?

    Via filling serves both mechanical and electrical purposes. Some key benefits include:

    • Supports pad-over-via and via-in-pad designs
    • Prevents solder leakage during wave soldering
    • Avoids short circuits under fine-pitch components like BGAs
    • Prevents flux residue accumulation in vias
    • Supports vacuum sealing during in-circuit testing (ICT)
    • Prevents solder paste wicking into vias
    • Reduces risk of solder ball ejection during wave soldering
    • Improves SMT assembly yield and stability

    Filled vias are also essential when designing stacked or staggered via structures in HDI boards. Designers often choose via filling when there’s limited space on the board and tight signal routing is needed. It’s common in smartphones, RF modules, and medical devices.

    Via Filling Types

    Manufacturers use different types of via filling based on the desired outcome and application. Here are the main types:

    1. Conductive Via Fill

    This method uses conductive materials like silver epoxy or copper paste. It enhances thermal and electrical conductivity. Conductive via fill technique can used in power components or RF signals.

    2. Non-Conductive Via Fill

    Here, the via is filled with non-conductive epoxy. It seals the hole but does not allow current flow. Commonly used under BGA pads to avoid shorts.

    3. Electroplated Copper Filling

    In this process, copper is electroplated inside the via, offering unmatched conductivity and strength. It’s the best option for stacked vias but also the most expensive.

    4. Resin Plugging

    Only one side of the via is filled with resin. It’s a cost-effective solution and most common used that reduces soldering defects but may not offer complete flatness.

    5. Tented Vias

    This is a basic method where the via is covered, not filled. Dry film solder mask covers the via but doesn’t prevent air pockets or improve flatness.

    PCB Via Filling Materials

    Choosing the right PCB via filling material depends on whether you need conductive or non-conductive properties. Materials include:

    • Silver epoxy (Conductive)
    • Copper paste (Conductive)
    • Resin-based epoxy (Non-conductive)
    • Electroplated copper (Advanced conductive)

    At Best Technology, we use reliable via filling compounds sourced from Taiyo, DuPont, and other trusted brands to ensure consistency and performance.

    Via Filling the Circuit Board Technique for PCB Fabrication

    What Is the Difference Between Via Filling and Via Plugging?

    In everyday factory usage, some engineers or sales reps might casually use “via plugging” and “via filling” interchangeably, especially when referring to BGA pad designs or HDI boards. However, from a technical and manufacturing standpoint, they serve different functions.

    1. Via Plugging

    This is the process of partially sealing a via—usually from one side—using non-conductive paste or resin. It’s mainly done to prevent solder wicking during reflow soldering. Plugged vias often remain hollow inside, and are not always planar (flat on the surface).

    Key points:

    • Seals only one end of the via
    • Often used under BGA pads to avoid solder leakage
    • Surface may not be flat or planar
    • Usually non-conductive paste
    • Cheaper and simpler than via filling
    Via Filling the Circuit Board Technique for PCB Fabrication

    2. Via Filling

    Via filling, on the other hand, means completely filling the via barrel (the entire hole) with conductive or non-conductive material. The goal is not only to seal but also to create a flat, solid surface for placing components or stacking additional vias on top.

    Key points:

    • Completely fills the via
    • Can be conductive (copper, silver epoxy) or non-conductive
    • Enables via-in-pad or stacked via structures
    • Supports high-density and multilayer PCB designs
    • More complex and costly than plugging
    Via Filling the Circuit Board Technique for PCB Fabrication

    So, if your board design requires a flat surface, thermal transfer, or electrical connectivity, you’re talking about via filling. If you just need to stop solder from leaking through a via, via plugging is enough.

    Factors That Affect the Via Filling Cost

    The cost of via filling in PCB manufacturing isn’t fixed. It depends on several technical and material-related factors that influence the complexity, time, and resources needed.

    1. Via Size and Quantity

    The diameter and number of vias play a huge role in overall cost. Smaller vias (like microvias) are harder to fill consistently and require more precision. When you need hundreds or even thousands of vias filled, the time and material usage increases.

    • Smaller vias <0.25mm demand tighter control and sometimes special filling equipment.
    • More vias mean more PCB via filling material, inspection, and process time.
    • Large quantities in high-density areas also increase the chance of defects, which may require rework or careful quality control.
    Via Filling the Circuit Board Technique for PCB Fabrication

    2. Board Thickness

    Thicker PCBs often have deeper vias, which means more material is needed to fully fill the holes. This not only increases the amount of epoxy or conductive paste required but may also need multiple fill passes to avoid voids.

    • Deep vias are harder to fill evenly, adding labor and process time.
    • Thick boards may also need extended curing cycles, further raising production time and energy costs.
    Via Filling the Circuit Board Technique for PCB Fabrication

    3. Layer Count

    As the number of layers increases, the need for precise via filling becomes more critical—especially for via-in-pad or stacked via structures found in HDI boards. Multilayer PCBs also demand layer-to-layer alignment, increasing the challenge during filling.

    • Higher layer count = more interconnections, which typically require more vias.
    • HDI designs may need filled and capped vias to build vertical stacks, which is costlier.

    4. Type of Filling Material

    Different PCB via filling materials come with different costs. Conductive pastes, like silver epoxy or copper-based compounds, are more expensive than non-conductive epoxies. Taiyo is a non-conductive material and it is cost-effective that popular used in the PCB manufacturing, while Dupont paste is more expensive because it has higher performance.

    Manufacturing Considerations for Via Filling

    Getting via filling right isn’t just about selecting a material—it involves careful planning at every step of the PCB manufacturing process.

    1. Via Diameter

    The diameter of the via plays a direct role in how successful the filling process will be. Smaller vias, especially microvias, are difficult to fill completely due to limited space for paste or copper to flow. If the via is too narrow, air can get trapped inside, leading to voids or incomplete filling.

    • Too small: May not allow enough material to enter, causing poor fill
    • Too large: Increases material usage and may affect board strength

    Manufacturers and designers need to balance via size and design constraints. Advanced production tools and tightly controlled dispensing techniques are often required to handle small-diameter vias.

    2. Pad Design (Especially if the Via Is Under a Pad)

    When a via is placed directly under a pad—a layout common in BGA and QFN designs—the stakes are higher. This layout is known as via-in-pad, and it requires precise filling and surface planarization to ensure a flat, solderable area. Incomplete filling can lead to solder voids or poor contact and misalignment can cause solder bridging or open connections

    3. Filling Process Sequence (Before or After Copper Plating)

    Another key factor is the process sequence—whether via filling happens before or after copper plating. This choice affects the electrical performance, mechanical strength, and yield rate.

    • Pre-plating fill: Usually involves non-conductive epoxy. Simpler, but not suitable for current-carrying vias.
    • Post-plating fill: Preferred for conductive via fill, as it adds copper first and fills later for stronger, continuous conductivity.

    Some manufacturers use a hybrid method depending on the function of the via (e.g., thermal transfer vs. signal routing). So, tell your suppliers what’s your purpose of filled vias and what’s function of it.

    4. Flatness Requirement (Some Applications Need Polishing)

    Not all boards need a flat surface after via filling—but when they do, the stakes go up. For designs that involve via-in-pad, stacked vias, or fine-pitch components, surface flatness is essential for proper soldering and electrical contact. Without polishing, filled vias may cause component misalignment and surface bumps can lead to cold solder joints.

    At Best Technology, we conduct DFM checks to optimize via placement and reduce risk during assembly. And our engineers understand these complexities and work closely with customers to deliver high-quality via filling, whether you’re designing for high-speed signals, thermal management, or stacked microvia configurations.

    Failure Analysis of Filled Vias

    Even when a via is properly designed and filled, issues can still occur during production or field use. Understanding the common types of failure in via filling helps reduce defects and improve long-term PCB performance.

    1. Void Formation

    Voids are air pockets left within the via after the filling process. As per IPC-6012D, for Class 2 and 3 products, voids should not exceed 5% of the via volume, and no single void may exceed 0.5 mm in length.

    • Causes: Entrapped air, poor wetting, low-pressure filling
    • Impacts: Weak thermal transfer, increased resistance, reduced mechanical strength
    • Detection: Best Technology utilizes X-ray inspection for detecting micro-voids as small as 10 ”m
    Via Filling the Circuit Board Technique for PCB Fabrication

    2. Incomplete Filling

    Incomplete via filling happens when the filler does not fully occupy the via barrel. IPC-6012 does not directly specify fill rate, but in practical terms, Class 3 boards typically require ≄90% via fill, especially in via-in-pad configurations.

    • Causes: Underdosed filler, poor alignment, rapid curing
    • Consequences: Electrical discontinuity, weak solder joints
    • Prevention: Proper volume control, optimized dispensing, degassing

    In advanced HDI boards, even a 15% fill gap can impair signal transmission or cause surface depressions, which affect planarity during BGA soldering.

    3. Cracks Under Thermal Stress

    Cracking often develops when materials expand and contract at different rates. IPC-6012 Class 3 boards must withstand 6× thermal cycles between –55°C and +125°C without structural or electrical failure.

    • Cause: CTE mismatch between filler and copper, rapid reflow ramp rates
    • Impact: Intermittent signal loss, potential long-term circuit failure
    • Testing: We run thermal cycling tests aligned with IPC-TM-650 2.6.7.2 guidelines to verify reliability

    4. Delamination After Reflow

    Delamination, a severe form of failure, involves separation between PCB layers, especially near filled vias. According to IPC-6012, delamination is unacceptable in Class 3 boards and must be prevented through proper lamination and moisture control.

    • Triggers: Moisture absorption, rapid heating, epoxy expansion
    • Typical scenario: After reflow or during high-temperature use
    • Detection: Destructive cross-sectioning and C-SAM (scanning acoustic microscopy)

    FAQs

    1. What is the most common type of via fill in PCBs?

    Non-conductive resin epoxy is the most widely used, especially for standard designs that don’t require thermal or electrical flow through the via.

    2. When should conductive via filling be used?

    When your design needs heat dissipation, power transfer, or high signal integrity, such as in RF or power boards.

    3. Is via filling necessary for all PCBs?

    No. It’s only needed when there’s a functional or layout reason, like vias under BGA pads or stacked via structures.

    4. Can via fill improve thermal management?

    Yes. Conductive via filling using copper or silver epoxy can transfer heat efficiently, helping prevent hotspots in high-power designs.

    5. How do I know which via filling type is right for my project?

    It depends on your board’s function. If you’re unsure, the engineering team at Best Technology will review your files and suggest the best option based on your goals.

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    What is PCB Heat Sink Pad? How to Design a Thermal Relief Pad?
    Monday, April 21st, 2025

    What is PCB Heat Sink Pad?

    In high-power electronics, heat is a persistent issue. When left unmanaged, it leads to failure, reduced life span, or poor performance. One of the smart ways to address this is by using a PCB heat sink pad. Sometimes referred to as thermal relief pads, these are conductive areas on a printed circuit board that channel heat away from components. They play a critical role in thermal management, especially in compact and high-density board layouts.

    These pads are often seen near power components, processors, or any part prone to heat buildup. By connecting to thermal vias or copper pours, they guide excess heat to ground or large copper areas. Thermal pads improve overall stability without the need for bulky external coolers. A well-designed thermal pad saves cost, space, and ensures better thermal cycling performance.

    What is PCB Heat Sink Pad?

    Importance of PCB Heat Sink Pad

    The importance of a PCB heat sink pad lies in its ability to support both thermal and electrical performance. As devices get smaller and more complex, the demand for thermal balance grows. Traditional cooling methods, like fans or heatsinks, aren’t always viable in a tight layout. That’s where these pads step in.

    They serve as an internal heat escape path. By reducing the junction temperature of critical parts, the heat sink pad ensures devices function at optimal levels. Without it, hot spots develop, possibly leading to delamination or component drift. In automotive, aerospace, or industrial environments, this can’t be ignored.

    Another key advantage is manufacturing. During reflow soldering, thermal pads help maintain consistent heating. This improves solder joint quality, avoiding cold joints or solder bridges.

    What Is the Function of a PCB Heat Sink Pad?

    The core function of a PCB heat sink pad is to pull heat away from the component body. This prevents overheating and promotes reliability. A pad usually sits beneath a hot-running device and connects to a ground or power plane through thermal vias. These vias act like vertical pipes that carry heat down to larger copper surfaces.

    Besides thermal performance, the pad also serves mechanical purposes. It supports the component body, helps with proper alignment during placement, and aids in reflow stability. In power ICs, LEDs, and RF modules, such a pad is more than a convenience—it’s a necessity.

    Often placed under QFNs, D-Pak, or Power MOSFETs, thermal pads are essential for packages where direct contact to the PCB is required for heat dissipation.

    PCB Thermal Pad vs Heatsink

    Understanding the thermal pad vs heatsink comparison helps in design decisions. A thermal pad (on PCB) is a built-in copper area, often plated and connected via thermal vias. It is internal and does not add extra height to the device. It’s subtle, efficient, and passive.

    PCB Thermal Pad vs Heatsink

    A heatsink, on the other hand, is a physical attachment—usually a metal block or finned structure—mounted on top of the component. It dissipates heat through air convection. While highly effective, heatsinks increase weight and require space. They may also need fasteners or thermal paste for better performance.

    PCB Thermal Pad vs Heatsink

    In low to medium-power circuits, thermal pads do the job silently. When current levels increase or the ambient conditions are harsh, heatsinks may be added. However, both solutions often work together. A pad draws the heat from the chip, and the heatsink then transfers it to the air.

    Why Do We Need Thermal Pad on PCB?

    We need thermal pads on PCBs to manage heat efficiently within confined board layouts. As chips grow more powerful and boards become smaller, heat density rises. Left unchecked, this can stress the materials, warp the PCB, or trigger thermal shutdowns in sensitive ICs.

    Thermal pads provide a compact and cost-effective solution. Unlike external cooling systems, these pads are part of the board design. They reduce the thermal resistance between the component and the ground plane, making heat transfer faster and more efficient.

    In LEDs, they stop lumen drop due to temperature spikes. In CPUs or RF amplifiers, they prevent drift in performance. Across industries, from smartphones to satellites, thermal pads are silent protectors against damage caused by thermal fatigue.

    Design Consideration of Thermal Relief Pads on PCB

    The design of thermal relief pads is not just about placing a copper square under a part. It demands precision. Several factors shape the design.

    1. Pad Size: The area should match the component’s thermal tab. Oversized pads can cause solder wicking; undersized ones fail to transfer heat efficiently.

    2. Vias Count and Diameter: Vias enhance heat transfer. Placing multiple small vias (0.3mm diameter with 6+holes) within the pad connects it to inner or bottom layers. These must be filled or tented to avoid solder leakage.

    Design Consideration of Thermal Relief Pads on PCB

    3. Copper Weight: Thicker copper layers enhance thermal conduction. A 2oz or 3oz copper layer works better than standard 1oz in high-heat zones.

    4. Solder Mask Clearance: The pad must be free from mask to allow full thermal contact.

    5. Connection to Planes: The pad should tie to ground or power plane, depending on the circuit. Use thermal relief spokes when needed to balance heat dissipation and solderability.

    6. Component Package Type: Each package, whether QFN or TO-263, demands unique pad sizing and via patterns. Manufacturer datasheets offer recommended layouts—follow them closely.

    When to Use Thermal Relief PCB?

    Using a thermal relief PCB becomes necessary in several scenarios. One key use is in multilayer boards where copper planes absorb too much heat. Without thermal relief, soldering becomes difficult as heat spreads too quickly. This leads to cold joints or poor wetting.

    Thermal reliefs help balance the heat flow. They allow soldering while still ensuring strong thermal performance. Another situation arises with through-hole components connected to large copper areas. Thermal relief spokes prevent the pad from acting like a heat sink during soldering.

    Power applications like inverters, motor controllers, and regulators benefit from thermal relief PCBs. So do high-brightness LED arrays. In RF boards, where impedance matters, thermal pads also stabilize the electrical response by providing consistent grounding.

    Use them when heat buildup could impair function or reduce board life. Proper relief design improves both manufacturing and operational performance.

    What Does Best Technology Offer?

    At Best Technology, we provide high-performance thermal solutions that elevate your product’s efficiency and reliability. With over 18 years of industry leadership, our expertise in PCB heat sink pads and thermal relief pads ensures your devices stay cooler, last longer, and perform better under pressure. Whether you’re in aerospace, automotive, or consumer electronics, we deliver custom-designed metal core PCB solutions that meet your most demanding thermal management needs.

    In additional to design thermal pads on PCB to achieve high heat dissipation, we also offer ceramic PCB and metal core PCB (including aluminum PCB, copper core PCB, sinkpad PCB), which have very good thermal conductivity to dissipate the heat fastly. If you want to know more about metal core PCB, ceramic PCB or thermal pads design guide, you are welcome to leave your comments below or contact us at sales@bestpcbs.com.

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    Posted in best pcb, bestpcb, Design Guide, FAQ, mcpcb, Metal Core PCB | No Comments »

    Copper Foil PCB | HTE vs RTF Copper Foil | Copper Foil PCB Manufacturers
    Monday, April 14th, 2025

    What is Copper Foil PCB?

    A copper foil PCB is a type of printed circuit board where copper foil is laminated onto the base material to form the conductive layer. This copper layer is what carries electrical signals and power between different parts of the board. Without it, a PCB wouldn’t function at all.

    The copper is typically applied through lamination, where thin sheets of copper foil are bonded to a substrate, usually made of fiberglass-reinforced epoxy resin like FR4. This copper layer is then etched to create precise paths, known as traces, that connect components across the board.

    There are also different thicknesses of copper foil used, which affect the board’s ability to carry current and dissipate heat. The standard thickness is usually 1 oz/ftÂČ (about 35ÎŒm), but heavier copper options like 2 oz or 3 oz are often used in power electronics or high-temperature applications.

    Copper Foil PCB | HTE vs RTF Copper Foil | Copper Foil PCB Manufacturers

    What is the Purpose of Copper Foil in PCB?

    The main role of copper foil is to carry electric current across the circuit. It’s the path for data, signals, and energy. Without copper foil, there would be no communication between components.

    Besides that, copper foil helps in thermal transfer. When current flows, heat is generated. Copper helps in spreading this heat evenly, reducing hot spots. That’s key in designs with dense parts or power-hungry chips. Also, copper layers add mechanical strength to the board, supporting solder joints and reducing flex.

    What are the Different Types of Copper Foils?

    Copper foil types vary based on how they’re made, how rough they are, and what kind of performance they offer in real PCB applications. Choosing the right type can make a big difference in signal clarity, layer adhesion, and long-term reliability. Let’s see the most common types used in the PCB industry:

    What are the Different Types of Copper Foils?

    1. Electrodeposited (ED) Copper Foil

    Electrodeposited copper foil is the most widely used type in standard rigid PCBs. It’s made through an electrochemical process where copper ions are deposited onto a rotating stainless steel drum. The side in contact with the drum becomes smooth, while the other side is naturally rough.

    ED copper foil is great for multilayer rigid boards, consumer electronics, and automotive circuits. When treated with surface chemicals, it bonds well to laminates and resists layer separation.

    2. Rolled Annealed (RA) Copper Foil

    RA copper foil is made by mechanically rolling solid copper into very thin sheets and then annealing it (heating and cooling) to relieve stress. You’ll find RA copper in flex circuits, flex-rigid PCBs, wearable electronics, and mobile devices. When boards must flex without breaking, RA is the go-to.

    3. Reverse Treated Foil (RTF)

    RTF is a type of ED foil where the shiny side is treated instead of the rough side. This treatment adds micro-etching or chemical bonding to enhance adhesion between the copper and the laminate. RTF is popular in HDI (High-Density Interconnect) boards, high-speed digital circuits, and RF designs where signal loss must be controlled.

    4. Very Low Profile (VLP) and Ultra-Low Profile (ULP) Copper Foils

    These are smoother versions of standard ED foils, created to reduce conductor roughness. VLP and ULP foils are still electrodeposited, but they go through extra steps to minimize surface peaks and valleys. They are used in high-speed digital systems, data centers, 5G antennas, and any application where clean signal transmission matters.

    5. High-Temperature Elongation (HTE) Copper Foil

    HTE copper foil is a variant of ED copper, enhanced for high thermal and mechanical stress. It resists cracking under repeated heating and cooling cycles. HTE is preferred for automotive, power electronics, and multilayer PCBs that go through reflow soldering or see high current loads.

    6. Resin-Coated Copper Foil (RCC)

    RCC combines copper foil with a thin layer of resin. This resin bonds directly to the core without needing prepreg sheets, which simplifies the lamination process. Mainly in mobile phones, compact devices, or where thin layers and high accuracy are needed.

    Here is a summary comparison table between them:

    Copper Foil TypeStrengthFlexibilitySmoothnessSignal PerformanceApplication
    EDHighLowModerateStandardRigid PCBs
    RAMedium  HighHighGoodFlex PCBs
    RTFHighMediumTreated  ExcellentRF, HDI
    VLP/ULP  MediumMediumVery HighSuperior5G, high-speed
    HTEVery HighLow  ModerateStandardPower boards
    RCCLowMediumHighGoodThin mobile boards

    What is the Roughness of Copper Foil in PCB?

    ‌The roughness of copper foil on PCB ‌ refers to the unsmoothness of the copper foil surface, Copper foil roughness affects how well signals move through the board. In high-speed designs, surface texture matters a lot. Rough copper increases insertion loss. This weakens the signal and causes noise.

    What is the Roughness of Copper Foil in PCB?

    Roughness is usually measured in microns, which is usually quantified by Ra, Rz and Rq. Lower values are better for RF or high-speed data.

    • ‌Ra‌: The arithmetic average of the absolute value of the contour deviation over the sampling length, applicable to copper foil surface.
    • ‌Rz‌: Sum of the average of the 5 largest profile peak heights and the average of the 5 largest profile valley depths over the sampling length for copper foil rough surface.
    • ‌Rq‌: Means RMS (Root means square) value, it also is a roughness index.‌

    PCB Copper Thickness Chart

    Copper thickness is often given in ounces per square foot. But that doesn’t mean much until you convert it. Here’s a helpful chart:

    Copper Weight (oz/ftÂČ)Thickness (”m)Thickness (mil)
    0.5 oz~17 ”m~0.67 mil
    1 oz~35 ”m~1.37 mil
    2 oz~70 ”m~2.74 mil
    3 oz~105 ”m~4.11 mil
    4 oz~140 ”m~5.48 mil
    • For single & double sided PCB, the copper foil thickness is about 35um, 50um, 70um;
    • For multi-layer PCB, its outer layer copper thickness is 35um, and inner layer copper thickness is 17.5um (1/2oz).

    Designers choose copper weight based on current flow and thermal limits. Thicker copper is used in power PCBs. Thinner layers are more common in signal circuits or HDI boards.

    HTE vs RTF copper foil

    When it comes to choosing the right copper foil for high-performance PCBs, HTE (High-Temperature Elongation) and RTF (Reverse Treated Foil) are two of the most commonly used options.

    • HTE Copper Foil

    HTE copper foil is a specially processed electrodeposited foil that’s engineered to handle high thermal and mechanical stress. The term “high-temperature elongation” refers to the foil’s improved flexibility and stretch resistance when exposed to heat.

    It’s treated chemically to improve adhesion strength, making it more reliable during multiple soldering cycles. The surface has a consistent profile that bonds well with different dielectric materials.

    Key Features of HTE Foil:

    • Strong peel strength
    • Durable under repeated heating
    • Excellent for plated-through-hole (PTH) reliability
    • Withstands lamination and solder reflow cycles
    • RTF Copper Foil

    RTF, or Reverse Treated Foil, is also made through an electrodeposition process, but with one key difference: the shiny side gets treated instead of the rough side. This treatment applies a fine, uniform microstructure that enhances bonding without creating high surface roughness.

    This smoother surface makes RTF a preferred option in high-speed signal and RF PCB applications where low signal loss is critical.

    Key Features of RTF Foil:

    • Lower surface roughness
    • Better electrical performance at high frequencies
    • Improved signal integrity
    • Balanced peel strength and performance

    PCB Copper Electrical Conductivity

    Copper has one of the highest electrical conductivities of any metal. That’s why it’s the go-to choice for PCBs. The typical conductivity of copper used in PCBs is about 5.8 x 10⁷ S/m (Siemens per meter).

    This high conductivity allows small traces to carry high current with low voltage drop. It also reduces signal distortion, which is key in high-speed or RF applications.

    Still, conductivity depends on purity. Most PCB foils use 99.9% pure copper. If copper is oxidized or poorly handled, conductivity drops. That’s why clean processes and proper lamination are important.

    How to Calculate Copper Thickness in PCB?

    The thickness of copper in PCB can be calculated by the following methods:

    1. Calculation of copper plating thickness by current density and plating time:

    Plating thickness (um) = current density (ASF) x plating time (min) x plating efficiency × 0.0202‌. This formula takes into account the amount of electricity, equivalent, molar mass, density and other factors. The specific calculation process involves the product of current density, plating time and plating efficiency, then multiplying by a factor 0.0202‌.

    ‌2. Thickness calculated by weight of copper foil:

    In the common option “copper-covered FR4, single-sided,1 oz”,1 oz indicates the thickness of the copper foil. 1 oz = 28.35 g/ftÂČ, copper foil density of 8.93 g/cmÂł, 1 square foot = 929.03 cmÂČ. Thus, 1 oz copper foil thickness = 28.35/8.93/929.03 ≈ 35um or 1.35mil ‌. Common PCB thicknesses include 1/2Oz = 17.5um, 1 oz = 35um, 2oz = 70um, and 3 oz = 105um.

    How to Calculate Copper Thickness in PCB?

    In addition to these two methods, you can also use our online pcb copper thickness calculator to calculate the copper thickness.

    online pcb copper thickness calculator

    Copper Foil PCB Manufacturers

    Many trusted copper foil PCB manufacturers serve global markets. Some of the top names include:

    1. Isola Group: Known for high-frequency and low-loss materials.

    2. Kingboard: One of the world’s biggest copper clad laminate suppliers.

    3. Ventec International: Offers low-profile copper foils and thermal substrates.

    4. Mitsui Mining & Smelting: A top name in RTF and ultra-smooth foils.

    5. Best Technology: Based in Asia, with 18+ years in the industry. We supply high-quality copper foil PCBs, from 0.5 oz to over 6 oz.

    At Best Technology, we bring over 18 years of hands-on experience. We support standard and custom copper weights, including heavy copper for high-current boards. Our RTF and HTE options fit both signal-sensitive and power-heavy needs.

    With fast lead times, in-house testing, and global delivery, we’re more than just a PCB maker. We’re your reliable partner for copper foil PCB solutions. Reach out today to explore your next project with confidence.

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