Copper Metal Core PCB Design Guide & Thermal Solution

August 1st, 2025

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

Are you worried about these problems?

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

Best Technology can provide solutions

Precise Thermal Matching Service: Through thermal simulation modeling, we customize the copper layer thickness (available in 0.1-3.0mm), ensuring a 40% reduction in LED module junction temperature and a 50% reduction in lumen degradation.
High-Current Wiring Technology: Utilizing an immersion gold (Immersion Gold) + OSP process, it supports a continuous current of 5A/mm², eliminating overheating issues in power modules and increasing yield to 99.2%.
Lightweight Structural Design: Copper foil micro-etching technology achieves 50μm line/space widths. A multi-layer stacking solution reduces drone battery pack size by 20% and extends flight time by 15%.

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

What Is Copper Metal Core PCB?

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

Copper Metal Core PCB Specification

Parameter	Specification
Base Material	Copper (typically C1100 or similar high-purity copper)
Copper Core Thickness	0.5 mm, 1.0 mm, 1.5 mm, 2.0 mm, up to 5.0 mm (custom thickness available)
Circuit Layer Copper Thickness	1 oz, 2 oz, 3 oz, up to 10 oz (35 µm to 350 µm)
Dielectric Layer Thickness	0.05 mm to 0.5 mm
Thermal Conductivity of Dielectric	1.0 W/m·K to 5.0 W/m·K or higher
Thermal Conductivity of Copper Core	~400 W/m·K (excellent thermal performance)
Operating Temperature Range	-40°C to +150°C or higher depending on design
Surface Finish Options	HASL, ENIG (Electroless Nickel Immersion Gold), OSP, Immersion Tin/Silver
Solder Mask Color	Green, White, Black (custom colors available)
Board Size	Up to 600 mm × 1200 mm (larger sizes possible upon request)
Drilling Options	Mechanical drilling, laser drilling for micro vias
Layer Count	Single-sided, double-sided, multilayer (up to 4 layers typical)
Impedance Control	Available for RF/high-frequency applications
Certification Standards	ISO9001, UL, RoHS, IPC Class 2/3 compliant

Benefits of Copper Substrate PCB

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

Applications of Copper Metal Core PCBs

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

Copper Metal Core PCB Design Guide

Below is copper metal core PCB design guide:

1. Material & Substrate Selection

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

2. Thermal Management

Spread high-power components (e.g., power ICs) to prevent heat buildup. Place heat-generating parts on outer layers for direct cooling.
Thermal vias: 0.3mm diameter, ≥4 vias/cm², 30μm copper plating. For IGBTs, embed 1.5mm heat pipes (local temp rise ≤15°C).
Add 10μm graphene film on copper layers to boost thermal diffusion by 40%. Validate designs with ANSYS/Flotherm and IR thermography.

3. Stack-Up & Board Thickness

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

4. Routing & Signal Integrity

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

5. Vias & Solder Mask

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

6. Manufacturing & Testing

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

7. Special Applications

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

Copper Metal Core PCB Thermal Solution

1. Advanced Thermal Materials

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

2. Via Array Optimization

Thermal Vias: Deploy 0.3mm diameter vias in hotspots (density ≥4 vias/cm²), reducing thermal resistance by 90% compared to non-via designs.
Dynamic Spacing: Use hexagonal via patterns for heat flux >50W/cm²; rectangular arrays for <30W/cm². Maintain via spacing ≥2×via diameter +0.1mm.
Copper-Via Synergy: Thicken via walls to ≥30μm when outer-layer copper exceeds 35μm. Reduce via spacing to 0.8mm for 35μm copper layers.

3. Heat Pipe Integration

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

4. Thermal Path Engineering

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

5. Simulation & Validation

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

6. Manufacturing Adjustments

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

How to Make A Copper Metal Core PCB?

1. Material Preparation

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

2. Inner Layer Fabrication

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

3. Lamination

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

4. Drilling & Plating

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

5. Outer Layer Fabrication

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

6. Solder Mask & Silkscreen

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

7. Surface Finish

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

8. Routing & Testing

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

9. Packaging & Shipping

Vacuum Packing: Seal boards in anti-static bags with desiccants.
Labeling: Include PCB specs, date codes, and compliance marks (RoHS, UL).

Why Choose Best Technology as Metal Core PCB Manufacturer?

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

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

Tags: copper metal core pcb, Metal Core PCB
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Consistent Quality Star MCPCB Manufacturer for Prototype

August 1st, 2025

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

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

Consistent Quality Star MCPCB Manufacturer for Prototype

What is a Star MCPCB?

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

What is the Material of Standard Star MCPCB?

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

What are the Star MCPCB Dimensions?

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

How to Do the MCPCB Design?

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

What Are the Manufacturing Processes of the MCPCB LED Star?

Producing an MCPCB LED star involves several steps:

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

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

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

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

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

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

What Are the Applications of the MCPCB Star Board?

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

LED flashlights
Spotlights
Automotive lighting
Decorative lighting
Medical devices

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

Where to Get MCPCB Star Board?

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

1. Full-Service Support from Start to Finish

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

2. Quick and Responsive Communication

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

3. Solving Common Customer Pain Points

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

4. Certified Quality You Can Trust

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

5. Consistent Quality for Every Order

Whether it’s a standard star MCPCB or a custom board, we deliver on time.
Quality is consistent, even for low-volume or prototype batches.

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

Tags: Star MCPCB
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MCPCB Design, MCPCB Manufacturing Process

August 1st, 2025

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

MCPCB Design, MCPCB Manufacturing Process

How to make mcpcb?

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

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

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

How is a mcpcb manufactured step by step?

Let’s break the process down into clear steps:

Metal Core Preparation

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

Dielectric Layer Application

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

Copper Cladding

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

Circuit Imaging and Etching

Photoresist is applied to the copper surface.

UV light exposes the circuit design.

Unwanted copper is etched away, revealing the desired pattern.

Drilling

Precise holes are drilled for component mounting and vias.

Plating and Solder Mask

Copper plating reinforces hole walls.

A protective solder mask is applied, ensuring insulation and component alignment.

Surface Finish

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

Testing and Inspection

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

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

What materials are used in MCPCB manufacturing?

The choice of materials is what gives MCPCBs their edge.

Metal Core (Base Layer)

Usually aluminum for cost-efficiency and solid heat dissipation.

Copper is used for high-end applications requiring better conductivity.

Dielectric Layer

The thin insulation layer offers high thermal conductivity but must resist high voltages.

Common materials include ceramic-filled polymers.

Copper Layer

Carries the electrical signals and forms circuit traces.

Thickness varies depending on current-carrying requirements.

Surface Finish

Prevents oxidation and ensures strong solder connections.

ENIG, HASL, and OSP are common options.

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

What is core in manufacturing process?

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

Heat Dissipation: Pulls heat away from components and spreads it evenly.

Mechanical Support: Strengthens the board and reduces vibration risks.

Electrical Isolation: Combined with dielectric materials to ensure circuits don’t short.

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

How is the chipset protected during MCPCB making?

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

Low Thermal Resistance Layers: These layers keep chipsets cool by drawing heat down quickly.

Strong Adhesion: Prevents delamination and cracking under stress.

Stable Solder Pads: Ensures chips stay in place during reflow soldering.

Controlled Expansion: Metal cores reduce thermal expansion that could otherwise harm chip connections.

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

What sets MCPCB apart from PCB manufacturing?

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

Thermal Management: MCPCBs are built for heat. Regular PCBs are not.

Material Core: FR4 vs. metal (aluminum or copper).

Applications: MCPCBs are used in LEDs, power supplies, automotive, and RF circuits. Traditional PCBs serve consumer electronics and low-heat applications.

Durability: MCPCBs hold up better in demanding environments.

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

What is the difference between FR4 and Mcpcb?

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

Thermal Conductivity:

FR4: Poor

MCPCB: Excellent

Structure:

FR4: All dielectric layers

MCPCB: Metal core + dielectric + copper

Use Cases:

FR4: Phones, computers

MCPCB: LEDs, automotive, industrial devices

Durability:

MCPCBs are more resistant to mechanical and thermal stress.

How does MCPCB manufacturing improve heat dissipation?

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

This design drastically reduces the risk of:

Component burnout
Solder joint failure
Signal degradation

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

LED lighting
Automotive sensors
Power converters

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

Conclusion:

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

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

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

Tags: chipset manufacturing process, mcpcb manufacturing, mcpcb manufacturing process, pcb manufacturing process
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What is an aluminium substrate PCB? Metal core PCB

August 1st, 2025

An aluminium substrate PCB is a metal core PCB that uses aluminum as its base layer instead of fiberglass. This design improves heat dissipation, strengthens the board, and enhances reliability.

What is an aluminium substrate PCB? Metal core PCB

It’s widely used in high-power applications like LED lighting and power supplies because it keeps components cooler and extends their lifespan. With excellent thermal performance and solid durability, aluminum PCBs are a smart choice for demanding electronic designs.

What is aluminum substrate?

The aluminium substrate in a PCB refers to the base layer made from aluminium instead of standard fiberglass. In a typical PCB, this layer would be FR4 or other resin materials. But with aluminium substrate PCBs, the core material is metal—specifically aluminium.

This aluminium base gives the PCB a solid foundation. It’s known for exceptional thermal conductivity and mechanical strength. When electronics generate heat (which they always do), this base layer helps pull the heat away fast. That means better performance, less risk of damage, and a longer product lifespan.

Aluminium also gives the board added durability. In harsh environments, it resists physical stress and corrosion better than many other substrates.

What is substrate in PCB?

To put it simply, a substrate in a PCB is the backbone. It’s the main layer that supports everything else. Think of it as the canvas where all the components and copper traces are placed.

The choice of substrate affects how a PCB behaves—its strength, heat resistance, flexibility, and even cost. Most traditional PCBs use FR4, a fiberglass-reinforced epoxy laminate. But when you need better thermal performance, a metal core like aluminium becomes the better option.

The aluminium substrate works by absorbing and dispersing heat, unlike FR4, which traps it. This becomes crucial in power devices, LEDs, and RF systems.

What is the difference between aluminum and FR4 PCB?

The contrast between aluminium and FR4 PCBs is more than just materials—it’s about function, reliability, and endurance.

Material: Aluminium PCBs have a metal core. FR4 PCBs use a glass epoxy material.

Thermal Conductivity: Aluminium wins. It conducts heat away quickly. FR4 holds onto heat, which can cause issues in high-power circuits.

Durability: Aluminium is tougher. It resists wear, shock, and even moisture better.

Weight: FR4 is lighter and more flexible, which is good for some consumer electronics.

Cost: Aluminium PCBs tend to be more expensive to produce but save money by increasing product lifespan and reliability.

So, while both have their place, aluminium PCBs provide real advantages in power-driven or heat-sensitive applications.

Why is aluminum no longer used in integrated circuits?

There was a time when aluminium was the go-to material for IC interconnections. It worked well in early semiconductor technologies. But as chips became smaller and faster, aluminium began to show limits.

Why? Copper is more conductive than aluminium. That means it handles signals faster and uses less power. It also allows for smaller, more compact designs.

Aluminium hasn’t disappeared, though. It’s just moved to a different job—serving as the base in PCBs where strength and heat transfer matter most.

Can high frequency PCB replace aluminium PCB?

High-frequency PCBs are designed to handle fast signals with minimal loss. They use specialized materials like PTFE (Teflon) to maintain signal integrity. But they don’t handle heat as well as aluminium PCBs.

So, can one replace the other? Not really. They serve different purposes. High-frequency PCBs are great for communication systems, radar, and RF devices. Aluminium PCBs are perfect when heat is a big issue—like in power supplies or LED systems.

That said, some advanced designs do combine both features. But in most cases, high-frequency and aluminium PCBs are used in their own unique ways.

Why use aluminium-substrate-PCB for LEDs?

LEDs are efficient light sources, but they generate concentrated heat. If not properly managed, that heat shortens lifespan, dims brightness, and even causes failure. That’s why aluminium-substrate-PCBs are a top choice for LED systems.

Also, aluminium PCBs provide a stable platform. They resist bending or cracking, even in high-humidity or high-temperature environments.

When used in LED strips, light panels, or automotive lights, aluminium PCBs ensure consistent brightness, lower energy loss, and better reliability.

Energy savings also come into play. With better heat dissipation, less power is wasted as heat. That means more energy is turned into light.

What are the pros and cons of aluminum PCB?

Like every technology, aluminium PCBs come with benefits and some limitations. Let’s look at both sides.

Pros:

Superior Heat Dissipation: This is the biggest win. Aluminium handles heat far better than FR4.

High Strength: Aluminium resists cracking, breaking, and vibration. That makes it ideal for industrial and automotive applications.

Longevity: Better cooling leads to longer component life. That reduces maintenance and repair costs.

Eco-Friendly: Aluminium is recyclable. That makes it a green choice for modern electronics.

Thermal Stability: It maintains performance even when temperatures rise.

Cons (but minimal):

Higher Cost: Aluminium PCBs cost more to produce than FR4.

Less Flexibility: Aluminium is rigid. It’s not suitable for bendable or foldable circuit designs.

Machining Complexity: Cutting and drilling aluminium is harder than standard boards.

If your application needs thermal stability, strength, and reliability, the pros easily outweigh the cons.

What are aluminum PCBs used for?

The reach of aluminium PCBs is wide. Their applications span multiple industries and product types.

LED Lighting: From household bulbs to industrial fixtures, aluminium PCBs keep LEDs cool and long-lasting.

Automotive Electronics: Think dashboard lighting, engine control systems, and electric vehicle modules.

Power Supplies: High-wattage power converters, inverters, and regulators benefit from aluminium’s heat handling.

Telecom Equipment: Signal amplifiers and antenna systems use aluminium PCBs for thermal control.

Medical Devices: Precision tools like scanners and monitors require stability and heat protection.

Consumer Products: High-performance gadgets like gaming devices, laptops, and audio systems often use metal core boards to ensure smooth operation.

No matter the product, if heat or durability is a concern, aluminium-substrate-PCB is often the right solution.

Conclusion:

Aluminium substrate PCBs are more than just metal-backed boards. They are performance boosters. They protect your devices from heat, shock, and failure. From LED lighting to telecom and automotive systems, these boards make sure devices run cooler, longer, and more efficiently.

If you’re designing products that need to handle heat, perform reliably, and last longer—aluminium PCBs are a smart, solid investment.

Need help choosing or customizing your aluminium-substrate-PCB? Contact us now at sales@bestpcbs.com

Tags: aluminium pcb, aluminium substrate pcb, aluminium-substrate-pcb, aluminum pcb, Metal Core PCB
Posted in bestpcb, FAQ, FR4 PCB, HDI PCB, mcpcb, Metal Core PCB | No Comments »

Copper Substrate PCB Design & Supplier, Fast Delivery

July 31st, 2025

Looking for copper substrate PCB solution? Let’s discover benefits, applications, design specifications and guide for copper substrate PCB.

Are you troubled with these issues?

Why does your 5G base station PCB frequently drop connections at high temperatures?
Why do LED car headlights always lose light so quickly?
Why is signal loss in high-frequency communication modules so high?

Best Technology can provide solutions

72-hour express delivery system: Equipped with a fully automated laser drilling line, mass production orders ship within 3 days (including special insulation layer curing).
Cost optimization expert system: Unique copper thickness gradient design reduces raw material costs by 12% while ensuring performance.
Full-process thermal management solution: Provides a complete cooling solution from thermal simulation to mass production, reducing measured temperature rise by 28°C.

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

What Is the Definition of Copper Substrate PCB?

A Copper Substrate PCB is a type of printed circuit board that uses copper as the base material instead of traditional substrates like FR4 (fiberglass) or ceramic. In this type of PCB, a thick copper layer (usually much thicker than standard copper foil used in conventional PCBs) serves as the core or foundation for building the circuit. The copper substrate provides excellent thermal conductivity, electrical performance, and mechanical stability, making it ideal for high-power and high-heat applications such as power electronics, LED lighting, and automotive systems.

What Are Benefits of Copper Substrate PCB?

Advantages of copper substrate PCB:

Superior Thermal Management

Conducts heat 8x faster than standard FR4 PCBs (398W/mK vs. 0.3W/mK).
Reduces junction temperature by 15-30%, extending component lifespan.

Enhanced Electrical Performance

Lower impedance & better signal integrity for high-frequency applications (5G, RF).
Stable dielectric properties (Dk≤3.5) minimize signal loss.

Mechanical Durability

Withstands 3x higher mechanical stress than aluminum substrates.
Ultra-low thermal expansion (16.5ppm/℃) prevents warping at high temperatures.

Cost-Effective Longevity

50% smaller heat sink requirements cut system cooling costs.
30% longer operational life reduces replacement frequency.

Design Flexibility

Supports fine-line etching (0.1mm traces) for compact high-power designs.
Compatible with multi-layer stacking for complex circuits.

What Are Benefits of Copper Substrate PCB?

What Are Applications of Copper Based PCB?

High-Power LED Lighting – Superior heat dissipation (398W/mK thermal conductivity) ensures stable performance in LED arrays and automotive headlights
Power Electronics – Used in server power supplies, inverters, and motor drivers, handling currents up to 200A with 6oz copper foil
Automotive Systems – Critical for EV charging (OBC/BMS) and engine control units (ECUs), withstanding high temperatures (150℃+) and vibrations
Telecommunication Base Stations – Supports 5G RF components due to low signal loss and EMI shielding
Industrial Equipment – Welding machines, laser drivers, and UPS systems leverage its high current capacity (30A/mm²)
Aerospace & Defense – Radar systems and high-energy lasers rely on its thermal stability and reliability (MTBF >100k hours)
Medical Devices – Ensures precision in imaging equipment and surgical tools with minimal thermal expansion

Copper Based PCB Design Specification

Parameter	Technical Specification	Note
Copper Thickness	1oz (35μm)/2oz (70μm)/3oz (105μm)	For high-current applications, ≥2oz is preferred; 1oz for cost reduction
‌Base Material	Oxygen-free copper (purity ≥99.5%)	High conductivity (58MS/m) minimizes signal loss
Thermal Performance	Thermal conductivity ≥398W/mK	Ensures ≤30℃ temperature rise for power devices
‌Insulation Voltage	≥3000VAC	Enhances safety and meets UL certification
Trace Width/Spacing	Minimum 0.1mm (4mil)	Supports high-density routing with laser drilling
‌Current Capacity	1oz: 1A/mm², 2oz: 2A/mm²	Reduces thermal risks in high-current designs
Surface Finish	ENIG/HASL/OSP	ENIG for reliability, HASL for cost sensitivity

Copper Substrate PCB Design Guide

1. Substrate Material

Prioritize high-thermal-conductivity copper substrates (e.g., aluminum, copper, or iron substrates) with thermal conductivity ≥1 W/(m·K).
Select copper foil thickness (typically 35μm–210μm) based on current-carrying requirements.
Insulation layers must be high-temperature-resistant and highly insulating (e.g., polyimide or modified epoxy resin).

2 Layer Stack-Up

Single-layer copper substrates: Suitable for simple thermal management (e.g., LED lighting).
Multi-layer copper substrates: Use prepreg for interlayer insulation to prevent delamination due to thermal stress.

3. Routing Optimization

Use wide traces (≥0.5 mm for 1 oz copper) for high-current paths to minimize heating.
Separate signal and power traces to avoid electromagnetic interference (EMI).
Avoid sharp 90° bends; use 45° chamfers or arc transitions.

4. Thermal Design

Place thermal copper pads beneath critical components (e.g., MOSFETs, ICs) and connect them to the copper substrate via thermal vias.
Thermal vias: Diameter ≥0.3 mm, spacing ≤1.5 mm, filled with thermally conductive material (e.g., silver paste).

5. Lamination & Etching

Lamination temperature: 180–200°C, pressure ≥30 kg/cm² to ensure adhesion between copper and insulation layers.
Use alkaline etching solutions to avoid undercutting and maintain trace width accuracy.

6. Surface Finish

Recommend ENIG (Electroless Nickel Immersion Gold) or OSP (Organic Solderability Preservative) for oxidation resistance and soldering reliability.
Apply anti-oxidation treatment (e.g., nickel or tin plating) to copper substrate surfaces.

7. Thermal Performance Testing

Conduct thermal cycling tests (-40°C to 125°C, ≥100 cycles) to verify material compatibility of thermal expansion coefficients.
Use infrared thermal imagers to detect hotspots; ensure temperature rise ≤30°C under full load.

8. Electrical Performance Verification

Impedance control: Adjust trace width/spacing based on signal speed, with tolerance ≤10%.
High-voltage testing: Insulation layer withstand voltage ≥500 V AC, leakage current ≤1 mA.

9. Cost Control

Simplify layer count; prioritize single- or double-layer designs.
Use standardized substrate sizes (e.g., 100 mm × 100 mm) for mass production.

10. Gerber File Requirements

Clearly mark copper substrate areas (e.g., .GTO layer) to distinguish signal and thermal layers.
Provide 3D assembly drawings with component height and thermal structure clearance annotations.

11. DFM (Design for Manufacturability) Check

Minimum trace width/spacing ≥0.2 mm, via diameter ≥0.3 mm.
Avoid placing critical components within 5 mm of substrate edges.

Why Choose Best Technology as Copper Substrate PCB Supplier?

Reasons why choose Best Technology as copper substrate PCB supplier:

24-Hour Rapid Prototyping: Accelerate product validation by 5x, beat competitors to market.
A Week Mass Production Turnaround: Eliminate supply chain bottlenecks during peak seasons.
Thermal Performance Optimization: Reduce power module temperatures by 25%, extend product lifespan.
Cost-Efficient Material Solutions: Achieve 15% higher profitability for LED/5G products.
High-Density Routing Expertise: Miniaturize IoT devices without sacrificing performance.
Global ISO/RoHS/REACH/UL Compliance: One-step certification for EU/US markets.
Smart DFM Support: Avoid costly redesigns with first-pass success guarantee.
Flexible Order Capacity: 100-100,000+ panel batch production capability.

Our Copper Substrate PCB Capabilities

Base material:	Copper
Thermal Conductivity (dielectric layer):	0.8, 1.0, 1.5, 2.0, 3.0 W/m.K.
Board Thickness:	0.5mm~3.0mm(0.02″~0.12″)
Copper thickness:	0.5 OZ, 1.0 OZ, 2.0 OZ, 3.0 OZ, up to 10 OZ
Outline:	Routing, punching, V-Cut
Soldermask:	White/Black/Blue/Green/Red Oil
Legend/Silkscreen Color:	Black/White
Surface finishing:	Immersion Gold, HASL, OSP
Max Panel size:	600500mm (23.62″19.68″)
Packing:	Vacuum/Plastic bag
Samples L/T:	4~6 Days
MP L/T:	5~7 Days

Our Quality Inspection & Certification

Certified & Compliant Standards: ISO 9001, ISO 13485, IATF 16949 Certified, and UL, REACH, RoHS Compliant.
AOI (Automated Optical Inspection): Detects surface defects like open/short circuits, missing components, and soldering issues.
X-Ray Inspection (Internal Defect Screening): Checks solder joint voids, cracks, and BGA/QFN hidden defects.
Peel Strength Test (Adhesion Assessment): Quantifies copper-clad laminate bonding force (ASTM D903).
Aging Test (Environmental Stress Screening): Includes thermal cycling (-40℃~85℃) and humidity exposure to validate long-term reliability.
Dimensional Verification (CMM/Profilometer): Measures thickness (±0.1mm), flatness, and hole alignment accuracy.

How to Get A Quote For MCPCB Project?

To ensure an accurate and fast quotation, please provide the following details:

‌1. Required Technical Specifications‌

Layer Count‌ (1L/2L/Multilayer)
‌Base Material‌ (Aluminum/Copper/Ceramic) & Thickness
‌Copper Weight‌ (1oz/2oz/3oz)
‌Board Dimensions‌ (Length × Width ± Tolerance)
‌Special Requirements‌ (Impedance control, blind/buried vias, etc.)

2. Files to Submit‌

Gerber Files‌ (RS-274X format preferred)
‌Drill Files‌ (Excellon format)
‌Stackup Diagram‌ (If multilayer)
‌Schematic & BOM‌ (For assembly projects)

3. Additional Information‌

Quantity‌ (Prototype/Bulk order)
‌Preferred Lead Time‌ (Standard/Expedited)
‌Surface Finish‌ (ENIG/HASL/OSP, etc.)

Why Choose Best Technology?‌

‌24H Rapid Prototyping‌ – Fast-track your product launch.
‌Cost-Effective Solutions‌ – Optimized designs save 10–15% on material costs.
‌Reliability‌ – 99.8% first-pass yield for high-power applications.

Get Your Quote Today!‌ Contact us at sales@bestpcbs.com with your project details.

Tags: copper base pcb, copper substrate PCB
Posted in best pcb, bestpcb, mcpcb, Metal Core PCB | No Comments »

What is an MCPCB LED Strip? MCPCB Design

July 31st, 2025

An MCPCB LED strip is an LED light strip built on a Metal Core PCB instead of a regular fiberglass board. The metal base, usually aluminum, helps pull heat away from the LEDs. This keeps them cooler, brighter, and longer-lasting.

What is MCPCB LED?

An MCPCB LED strip is a flexible or rigid lighting circuit that uses Metal Core Printed Circuit Boards (MCPCB) instead of traditional fiberglass boards. These boards are made with a metal base—often aluminum—layered with a dielectric material and topped with copper circuitry.

The main advantage? Superior heat dissipation. LED chips generate heat, and if it’s not managed properly, brightness fades and lifespan drops. The metal core acts as a thermal bridge, quickly pulling heat away from the LEDs.

Why use MCPCB for LED strip lights?

LED light strips are widely used for their compact size and bright output, but they also bring a problem: heat. Excessive heat shortens LED life, dims the light, and can even cause circuit failure.

Here’s where MCPCB LED steps in with its unique benefits:

High thermal conductivity: Metal cores rapidly remove heat from LED chips.

Longer lifespan: Cooler LEDs mean longer use.

More stable output: No flickering or fading over time.

Compact design support: Even tight spaces can house high-powered LEDs safely.

Durability: Metal cores are more resistant to physical damage than FR4 boards.

How does MCPCB design affect LED strips?

The MCPCB design is more than just the layout of circuits. Each layer of the MCPCB is chosen and designed for a specific function:

Metal base (usually aluminum): Carries the heat away.

Dielectric layer: Transfers heat while keeping electrical isolation.

Copper circuit layer: Routes electricity to the LEDs.

Even the thickness of the dielectric layer impacts how fast heat can move. A thinner dielectric means faster transfer, but it must still insulate properly. Similarly, thicker copper can handle higher currents without overheating.

Good MCPCB design ensures even temperature distribution. That means no LED on the strip gets too hot. Even light, long life, and better performance.

Can MCPCB design improve LED lifespan?

Absolutely. Heat is the main enemy of LED lifespan. Every degree of temperature rise reduces the life of an LED chip.

Traditional PCB materials like FR4 don’t handle heat well. Over time, they allow hotspots to build up. These hotspots degrade the LED’s light output and can eventually cause failure.

But MCPCB design changes the game. By channeling heat away from the LED source, it keeps the chip temperature lower. This cooler environment means:

No yellowing of lenses

No cracking of solder joints

No degradation of LED chip efficiency

So yes, MCPCB LED strips don’t just shine brighter—they shine longer.

MCPCB LED vs. regular LED PCB strip – what’s better?

Let’s compare a regular LED PCB strip to a metal core version:

Feature	Regular LED Strip (FR4)	MCPCB LED Strip
Heat dissipation	Poor	Excellent
Brightness over time	Decreases	Maintained
Durability	Fragile	Rugged
Power handling	Low	High
Cost	Lower upfront	Better long-term value

While FR4-based LED strips may seem cost-effective, they often end up needing frequent replacements—especially in high-power applications. MCPCB LED strips, on the other hand, are built to last.

How to choose the right LED PCB strip?

Choosing the right LED PCB strip depends on your application. Here are a few factors to consider:

Heat Load: If your strip is in a confined or warm space, go for MCPCB.

Power Requirement: More power means more heat. MCPCB handles high current safely.

Installation Area: Metal core strips are ideal for industrial, automotive, and high-brightness home uses.

Budget vs. Longevity: While MCPCB may cost more upfront, it saves money in the long run.

Brightness and Color Consistency: Heat can affect color temperature. MCPCB avoids this.

How to customize an MCPCB LED strip?

Customization is one of the most important aspects of MCPCB design. With the right manufacturer, you can tailor almost everything:

Board size and shape: Fit into curves, tight corners, or irregular enclosures.

Copper thickness: For heavy-duty current or low-voltage precision.

Thermal conductivity: Select different dielectric materials for performance.

LED configuration: Control spacing, brightness, and light pattern.

Mounting features: Add connectors, screw holes, or adhesive backs.

Surface finish: Choose between ENIG, HASL, OSP for different protection levels.

When you work with a professional manufacturer like Best Technology, your custom MCPCB LED strip lights will be the best they can be.

Where is MCPCB LED used most?

You’ll find MCPCB LED strips in places that demand both performance and reliability. Here are just a few common uses:

Automotive lighting: Headlights, tail lamps, and interior accents.

Commercial lighting: Display cases, signage, and architectural lights.

Medical devices: Surgical lights and diagnostic equipment.

Industrial machines: Workstation lighting, control panels.

Consumer electronics: High-end flashlights, monitors, smart mirrors.

Streetlights & floodlights: Large scale applications with heavy thermal loads.

Wherever durability meets brightness, MCPCB LED plays a vital role.

Conclusion:

MCPCB LED strips surpass traditional LED PCB light strips in every way with better heat management, longer lifespan, and greater durability.

Need support for MCPCB LED strip design or customization? Reach out to us at sales@bestpcbs.com

Tags: led pcb strip, mcpcb design, mcpcb led bulb, mcpcb led strip
Posted in best pcb, bestpcb, FAQ, mcpcb, Metal Core PCB | No Comments »

Copper Laminate PCB Design Guide丨MCPCB Manufacturer

July 31st, 2025

Looking for copper laminate PCB solution? This blog discover its material, specification, benefits, applications, design guide for LED lighting, manufacturing process.

Are you worried about these problems?

Uneven heat dissipation leads to a dramatic reduction in component lifespan. How can we overcome thermal management challenges?
High-frequency signal integrity is insufficient. How can we balance electromagnetic compatibility and transmission efficiency?
Low-volume customization leads to long lead times. How can we balance flexibility and cost control?

Best Technology can provide solutions include:

Gradient heat dissipation structure design: Through optimized three-dimensional heat conduction paths, it achieves a temperature drop of over 15°C in hotspots, extending device lifespan.
Low-impedance electromagnetic shielding layer: Utilizing high-purity aluminum-based nano-plating technology, signal transmission loss is reduced to 0.3dB/cm.
Agile and flexible production lines: Prototyping within 48 hours, supporting minimum orders of 10 pieces, and reducing mass production cycle time by 30%.

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

What Is Copper Laminate PCB?

A Copper Laminate PCB is a printed circuit board base material that consists of an insulating substrate (such as FR4, CEM-1, ceramic, or metal core) that is laminated with a thin layer of copper foil on one or both sides. This copper layer is later etched to create electrical pathways or circuit traces, which connect and support electronic components.

What Is Material of Copper Clad PCB?

Materials of Copper Clad Laminate (CCL) PCB

Base Substrate Materials:

Epoxy Resin (FR-4): Most common, combining glass fiber cloth with epoxy for rigidity and insulation.
Polyimide (PI): Used in flexible PCBs for high-temperature resistance and bendability.
Phenolic Resin: Low-cost option for paper-based CCLs, suited for simple circuits.
PTFE (Teflon): High-frequency applications due to ultra-low dielectric loss.

Reinforcement Materials:

Glass Fiber Cloth (E-glass): Primary reinforcement in rigid CCLs for strength and stability.
Paper/Cellulose: Used in cost-sensitive, low-performance boards.
Polyester/PET Film: Base for flexible CCLs in lightweight designs.

Conductive Layer

Electrolytic Copper Foil: Purity ≥99.8%, thickness ranges from 18μm (0.5oz) to 105μm (3oz).
Rolled Copper Foil: Smoother surface for high-frequency signals.

Specialty Materials

Metal-Core (Aluminum/Copper): For high-power LED and automotive PCBs, offering superior heat dissipation.
Ceramic-Based: High thermal conductivity for RF/microwave circuits.

Adhesive Systems

Modified Epoxy: Bonds copper foil to substrates, ensuring peel strength ≥1.0N/mm.
Acrylic/Polyimide Adhesives: Used in flexible CCLs for dynamic bending applications.

Copper Clad Laminate PCB Specification

Parameter	Standard Values
Base Material	Metal-Core (Cu)
Copper Foil Thickness	18μm–105μm (0.5oz–3oz)
Dielectric Constant (Dk)	3.8–4.5 (FR-4), 2.5–3.5 (PTFE)
Dissipation Factor (Df)	0.015–0.025 (FR-4), <0.005 (PTFE)
Thermal Conductivity	150–400 W/m·K (Metal-Core)
Peel Strength	≥1.0 N/mm (Cu-to-substrate)
TG Rating	Tg 130°C–170°C (Standard/High-Tg)
Flammability Rating	UL94 V-0 (Halogen-free options)

What Are Benefits of PCB Copper Clad Laminate?

Enhanced Signal Integrity: Lowers ground impedance, reducing noise and interference in digital circuits (e.g., pulse current paths are optimized).
Improved Heat Dissipation: Copper’s high thermal conductivity (≈400 W/m·K) helps distribute heat evenly, preventing hot spots.
Mechanical Stability: Reinforces PCB structural integrity during manufacturing, reducing warping and deformation.
EMI/RFI Shielding: Acts as a natural shield against electromagnetic interference, protecting sensitive components.
Design Flexibility: Supports high-density interconnects (HDI) and advanced techniques like blind/buried vias for compact electronics.
Cost-Effective Manufacturing: Simplifies processes (e.g., plating-filled vias for reliable connections) while maintaining performance.

What Are Applications of Copper Laminate PCB?

Telecommunications: 5G base stations, RF signal processing modules.
Automotive: Electric vehicle (EV) battery management systems, motor control units.
Lighting: High-power LED drivers, automotive headlight assemblies.
Aerospace: Satellite communication hardware, avionics control systems.
Consumer Electronics: Smartphone motherboards, IoT device circuitry.
Medical: MRI machine power supplies, implantable medical device interfaces.
Industrial Automation: Robotics motor drivers, factory automation control panels.
Renewable Energy: Solar inverter power conversion, wind turbine energy management systems.

Copper Laminate PCB Design Guide For LED Lighting

Below are copper laminate PCB design guide for LED lighting:

1. Material Selection

Base Material: Use electrolytic copper foil (ED Copper) with minimum thickness 1 oz (35µm).
Dielectric Layer: Select UL94 V-0 certified insulation (e.g., polyimide or ceramic-filled epoxy).
Copper Purity: ≥99.9% purity for thermal/electrical performance. Surface roughness (Ra) ≤1.6µm.

2. Layer Stackup

Single-Layer: Copper substrate (bottom) + dielectric + copper trace layer (top).
Multi-Layer: Avoid placing signal layers directly on copper substrate. Use “copper substrate – dielectric – copper foil” for dual layers.
Prohibition: No signal traces on copper substrate side.

3. Trace Routing

Current Capacity: Follow IPC-2221. Design traces ≥3mm/A for high-current paths (e.g., LED drivers).
Clearance: Maintain ≥2mm spacing between traces and copper substrate edges.
Geometry: Use 45° miters for bends; avoid 90° angles.

4. Thermal Management

Thermal Vias: Place via arrays (≥0.3mm diameter, ≤1mm pitch) under high-power LEDs. Connect directly to copper substrate.
Solder Mask: Exclude solder mask on copper substrate areas for direct thermal dissipation.
Copper Coverage: Allocate ≥40% of PCB area to copper substrate for heat spreading.

5. Solder Mask

Thickness: Control solder mask on copper substrate to 15–25µm.
Clearance: Keep solder mask openings ≥0.5mm from copper substrate edges.
Process: Avoid LPI (Liquid Photoimageable) solder mask on copper substrate side.

6. Via Design

Drilling: Mechanical vias ≥0.8mm; laser vias ≥0.15mm.
Teardrops: Add teardrop reliefs at via-to-trace junctions.
Grounding: Minimum 2 vias per high-power LED for thermal/ground connectivity.

7. Test Points

Placement: Locate test pads away from copper substrate areas.
Size: Test pad diameter ≥2mm; spacing ≥2.54mm.
Accessibility: Ensure test points are probe-friendly (no components nearby).

8. Manufacturing Tolerances

Outline: Board dimension tolerance ±0.1mm.
V-Cut: Depth ≤1/3 of total board thickness.
NPTH: Avoid non-plated through-holes (NPTH) near copper substrate.

9. Reliability Testing

Thermal Cycling: -40°C to +125°C, 1000 cycles.
Humidity: 85°C/85%RH for 500 hours.
Solderability: 260°C/10s reflow, 3 cycles.

10. Documentation

Annotations: Specify copper thickness, dielectric material, and thermal via locations.
Thermal Model: Provide 3D thermal simulation files (e.g., Ansys Icepak).
Assembly Notes: Highlight LED polarity, thermal pad alignment, and pressure requirements.

Copper Laminate PCB Design Guide For LED Lighting

Single Sided Copper Clad Laminate PCB Manufacturing Processes

Single-Sided Copper Clad Laminate PCB Manufacturing Processes

1. Material Preparation

Use FR-4 or CEM-1 substrate with 1 oz (35µm) electrolytic copper clad on one side.
Cut raw panels to working size (e.g., 400mm × 500mm) with ±1mm tolerance. Clean edges to remove debris.

2. Drilling

CNC drill component/mounting holes using carbide bits (0.3mm–3.2mm diameter).
Deburr holes with nylon brush or ultrasonic cleaner. Inspect for broken bits or residual copper.

3. Surface Cleaning

Alkaline wash (pH 10–12) to remove oils and fingerprints.
Micro-etch copper surface with sulfuric acid + hydrogen peroxide solution (Ra 1.6–3.2µm).
Dry at 80–100°C to prevent oxidation.

4. Circuit Formation

Apply dry film photosensitive laminate (35–50µm) or screen-print etch-resistant ink.
Expose to UV light through artwork film (1–5 seconds). Develop with sodium carbonate (0.8–1.2% concentration).

5. Etching

Use ferric chloride (FeCl₃) solution at 45–55°C or ammonium persulfate at 25–30°C.
Spray etch with 1.5–2.5 kg/cm² pressure for uniformity. Control line width (±10% tolerance) and undercut (<10% of line width).
Rinse with water and strip residual dry film with sodium hydroxide (2–3% solution).

6. Solder Mask Application

Spray or screen-print epoxy-based liquid photoimageable (LPI) solder mask (20–30µm thickness).
Expose to UV through solder mask film. Develop with sodium carbonate (1–2% concentration). Cure at 150°C for 60 minutes.

7. Surface Finish

HASL: Dip in molten Sn63/Pb37 solder (260°C) and blow hot air to remove excess.
OSP: Apply benzotriazole-based coating. Dry at 80°C for 10–15 minutes.

8. Profiling

Score board edges with V-Cut (30–60° angle) using hydraulic press. Maintain ±0.1mm dimensional tolerance.

9. Electrical Testing

Use flying probe tester (e.g., Takaya APT-9411) with 10–50V DC. Verify isolation resistance (>100MΩ) and continuity (<1Ω).

10. Quality Inspection

Visual check: No exposed copper outside solder mask, no voids/cracks, pad alignment ±0.05mm tolerance.
Dimensional check: Hole positions (±0.1mm), board size (±0.2mm).

11. Packaging

Vacuum seal boards in ESD-safe bags with desiccant. Label with lot number, date code, and RoHS compliance mark.

Single Sided Copper Clad Laminate PCB Manufacturing Processes

Why Choose Best Technology as MCPCB Manufacturer?

19-Year Metal Substrate Expertise: Avoid costly design iterations with battle-tested thermal management solutions.
Strict Quality Control: 100% AOI/X-ray inspection ensures flawless delivery, eliminating rework risks.
24-Hour Rapid Prototyping: Cut product validation time by 50% and accelerate market entry.
ISO 9001/14001 Certified: Global regulatory compliance simplified for seamless international sales.
Competitive Pricing: Achieve 20%+ cost savings through optimized production scaling.
Custom Thermal Management: Optimize heat dissipation for high-power applications (e.g., automotive, LED).
Flexible MOQ (5pcs–100K+): Reduce inventory risks with agile small-batch to mass-production transitions.
24/7 Engineering Support: Solve technical challenges proactively, shorten R&D cycles by 30%.

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

Tags: copper clad laminate pcb, copper laminate PCB
Posted in best pcb, bestpcb, mcpcb, Metal Core PCB | No Comments »

The 2025 Ultimate Guide to PCB Aluminium Substrate

July 31st, 2025

PCB aluminium substrate is a go-to solution for high-performance electronics, especially where heat needs quick handling. It is widely used in LED lighting, automotive, and power devices due to its excellent heat conductivity and long-lasting structure.

Best Technology is a leading aluminum PCB board factory in China. Out of necessity, we have the sophisticated equipment in our factory, and we have invited lean agility to better process our customers’ prototypes and large orders as of late. If you have received the prototypes manufactured by us, you will see our advantage in PCB aluminium quality. Our engineering professionalism and relentless dedication to on-time delivery for our PCBs are plain to see in our actions. If you have any recent inquiries regarding the PCB aluminium substrate, we are pleased to respond with a great quote as rapid as we can. Just sent the specific files and details to us at sales@bestpcbs.com.

The 2025 Ultimate Guide to PCB Aluminium Substrate

What Is PCB Aluminium Substrate?

PCB aluminium substrate is a special type of printed circuit board that uses aluminium as its base material. This metal base helps in managing heat more effectively compared to standard materials like FR4. It supports better thermal flow, which is key in modern compact devices. This substrate usually includes three layers: the aluminium base, a dielectric layer for insulation, and a copper layer for the circuit.

What Is the Difference: Aluminum PCB vs FR4?

Choosing between aluminium PCB and FR4 often depends on the application. Aluminum PCB vs FR4 mainly differs in heat management. FR4 is a common glass-reinforced epoxy material with low heat transfer. In contrast, aluminium PCB quickly removes heat from components. Aluminium boards also offer higher durability and support higher current loads. On the other hand, FR4 is more flexible for complex circuits but not suitable for high-power or high-temperature tasks.

Feature	Aluminum PCB	FR4 PCB
Base Material	Aluminum metal	Glass-reinforced epoxy resin
Thermal Conductivity	High (1.0–3.0 W/m·K)	Low (0.25–0.3 W/m·K)
Heat Dissipation	Excellent	Poor
Mechanical Strength	Strong and rigid	Moderate strength
Flexibility in Design	Limited	High (supports multilayer and flexible)
Current Carrying Capacity	High	Moderate
Cost per Unit	Higher than FR4	Lower than aluminum PCB
Typical Applications	LED lighting, power modules, automotive	Consumer electronics, communication
Temperature Resistance	High	Lower
Weight	Heavier	Lighter
Durability	Very durable	Less durable under high heat

What Is Aluminum PCB Dielectric Material?

The dielectric layer in an aluminium PCB is key for thermal transfer and electrical insulation. This layer sits between the aluminium base and the copper circuit. It is usually made from thermally conductive material, helping move heat away from the circuit. The quality and thickness of this layer affect both the performance and price of the board. At Best Technology, we use high-grade dielectric to ensure low thermal resistance and high reliability.

What Is the PCB Aluminium Substrate Price?

The PCB aluminium substrate price can vary based on factors like board size, copper thickness, and thermal needs. Basic aluminium boards for LEDs are quite affordable, while complex ones for power electronics cost more. Bulk orders often reduce the unit cost. At Best Technology, we offer competitive rates with added value from expert support and quality control.

How to Choose PCB Substrate Types?

Selecting PCB substrate types depends on your project needs. Consider heat levels, power load, size, and cost. If your design generates much heat or requires high strength, aluminium is ideal. For less heat and lower costs, FR4 might work. There are also ceramic and flexible substrates for special cases. Our engineers at Best Technology help customers pick the right substrate by reviewing their designs and offering practical advice.

Criteria	Aluminum PCB	FR4 PCB	Ceramic PCB	Flexible PCB
Thermal Conductivity	High	Low	Very High	Low
Heat Dissipation	Excellent	Poor	Excellent	Poor
Mechanical Strength	High	Moderate	High	Flexible (low rigidity)
Design Flexibility	Limited	High (multilayer possible)	Moderate	Very High
Cost	Medium to High	Low	High	Medium
Applications	LED, power devices, automotive	Consumer electronics, general use	High-frequency, medical, aerospace	Wearables, compact devices
Weight	Heavier	Light	Moderate	Light
Durability	High (for harsh environments)	Moderate	Very High	Lower (needs careful handling)

When to Use Aluminum Substrate PCB?

Use aluminum substrate pcb when thermal control is a priority. It’s perfect for LED lights, power supplies, automotive modules, and audio gear. These devices produce heat that needs quick removal to avoid failure. Aluminium boards help extend product life and ensure stable performance. They are also used in medical and military tools where dependability matters. In short, if heat affects your circuit’s life or performance, aluminium is worth considering.

Which Inspection Steps Are Included in the Aluminium PCB Production Process?

At Best Technology, every aluminium PCB manufacturing process follows strict inspection. The steps include:

Incoming material checks – ensuring aluminium sheets meet quality standards.
Copper circuit inspection – checking for cracks, shorts, or missing lines.
Dielectric thickness check – measuring thermal insulation uniformity.
Dimensional accuracy – verifying board size and hole placement.
Thermal test – confirming heat transfer capability.
Electrical test – verifying circuit continuity and insulation resistance.
Final visual check – ensuring the finish is smooth and defects-free.

We also offer custom test setups based on your project’s needs, helping catch hidden issues before delivery.

Why Choose Best Technology for Manufacturing Aluminium PCB Board for LED?

Choosing the right manufacturer for aluminium PCB board for LED can solve many hidden challenges. Many customers face late deliveries, unclear communication, and inconsistent quality. Best Technology solves these with a professional engineering team, fast production lines, and strict quality control.

On-Time Delivery
Fast production lines help us ship your boards on schedule, avoiding project delays. Best Technology has an on-time delivery rate of 97%.

Clear Communication
Our team responds quickly and keeps you updated at every step. Our sales are not mere messengers; we grasp the full knowledge of the PCB aluminium substrate. You don’t need to keep waiting for a viable solution or answer after the sales confirm with the engineers.

Strict Quality Control

We help you optimize aluminum PCB design to improve heat transfer and reduce cost. We use high-grade materials and help fix design issues before production. In each manufacturing process, there are strict QC checks, followed by ISO 9001, ISO 13485, IATF 16949, AS9100D, UL, REACH, and RoHS standards.

Professional Engineering Support

Our engineers have valuable experience in offering custom solutions for different applications, from prototype to box build. If you want to do custom aluminium PCB sheet sizes, just find Best Technology.

To conclude, Best Technology values your time and goals, aiming for a smooth and worry-free experience. Any doubts or questions you would like to inquire, just let us know at sales@bestpcbs.com.

Why Choose Best Technology for Manufacturing Aluminium PCB Board for LED?

In a nutshell, PCB aluminium substrate is a smart choice for modern electronics, offering strong heat control and durability. It’s perfect for LEDs, power tools, and more. Knowing the differences between aluminium PCB and FR4, understanding dielectric materials, and learning about PCB aluminium substrate price helps in making better decisions. Choosing the right partner, like Best Technology, ensures your boards are reliable, cost-effective, and delivered on time. We help customers overcome typical issues in aluminium PCB manufacturing by offering quality materials, expert support, and fast lead times. A warm welcome to get a free DFM analysis and a particular quote from us. Just share your Gerber Files, the detailed requirements, and the order quantity with us at sales@bestpcbs.com.

Tags: pcb aluminium substrate
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Single Sided Copper PCB Design & Manufacturer, Fast Delivery

July 30th, 2025

How to design a single sided copper PCB? Let’s discover spec, benefits, design guide and manufacturing process for single sided copper PCB board.

Are you troubled with these problem?

Is insufficient heat dissipation leading to a shortened product lifespan?
Is high-frequency signal transmission loss affecting performance?
Is it difficult to balance cost reduction and reliability?

Best Technology can provide service and solution:

Using a high-thermal-conductivity aluminum substrate (thermal conductivity ≥ 2.0 W/m·K) and optimizing copper foil thickness, we’ve achieved a measured temperature reduction of 15-30°C.
Low-k dielectric constant substrates and precise impedance control (tolerance ±5%) ensure stability in high-frequency scenarios like 5G and radar.
Intelligent layout algorithms and a standardized material library reduce mass production costs by 20% and pass 5,000-hour burn-in tests.

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

What Is Single Sided Copper PCB?

A ‌single sided copper PCB‌ is the simplest type of printed circuit board, consisting of a single conductive copper layer bonded to one side of an insulating substrate (usually FR-4 fiberglass or phenolic material). The opposite side remains uncoated, making it ideal for straightforward circuits. Components are mounted and soldered onto the copper side, while traces (circuit paths) are created by etching away unwanted copper.

Single-Sided Copper PCB Specification

Parameter	Specification
Base Material	FR-4 (Flame Retardant 4) or Phenolic Paper
Copper Thickness	18 μm (0.5 oz/ft²) to 35 μm (1 oz/ft²)
Trace Width/Spacing	Minimum 0.2 mm (8 mil) for traces; 0.15 mm (6 mil) for spacing
Solder Mask	Liquid Photoimageable (LPI) or Dry Film Solder Mask (optional)
Silkscreen	White, black, or yellow ink (optional)
Surface Finish	HASL (Hot Air Solder Leveling), ENIG (Electroless Nickel Immersion Gold), or OSP
Board Thickness	0.8 mm to 1.6 mm (standard)
Thermal Resistance	Tg 130°C (FR-4 standard)
Impedance Control	Not applicable (single-layer design)
Peel Strength	≥1.0 kgf/cm (copper-to-substrate adhesion)
Flammability Rating	UL-94 V-0 (self-extinguishing)
Applicable Standards	IPC-6012 (Class 2/3), RoHS, REACH

Advantages of Single Sided Copper PCB

Low Cost – Simplified materials and processes reduce costs by 30%-50% compared to double-sided PCBs, making it suitable for budget-conscious projects.
Easy Design Entry – Single-sided routing simplifies circuit design, allowing even novice designers to quickly design and shorten prototype verification cycles.
Fast Production – Streamlined processes and a high degree of automation allow for 3-5-day delivery for regular orders and 24-hour shipping for urgent orders.
Low Failure Rate – No vias or interlayer connections, resulting in minimal signal interference, high temperature and moisture resistance, and high reliability in industrial environments.
Environmentally Compliant – Recyclable materials, no electroplating contamination, and RoHS/REACH compliance ensure worry-free export.
Flexible Customization – Customizable substrates, surface treatments, and colors meet brand differentiation or specific environmental requirements.
Wide Application – Covering home appliances, consumer electronics, industrial control, and other fields, this solution provides a one-stop solution for low- to medium-density circuit needs.

Applications of Single Sided Copper PCB Board

Home Appliances – Washing machines, refrigerators, microwave ovens (simple control circuits).
Consumer Electronics – Electronic toys, basic remote controls, LED lighting drivers.
Industrial Control – Low-complexity sensors, motor controllers, power distribution units.
Automotive Electronics – Car lighting systems, low-speed electric vehicle battery management.
Power Supplies – Low-cost adapters, simple charger circuits (low-density designs).
Medical Devices – Basic diagnostic tools, portable health monitors (non-critical circuits).
IoT & Smart Home – Entry-level smart sensors, temperature/humidity monitors (low-data designs).

How to Design A Single Sided Copper Clad PCB?

Single sided copper clad PCB design guide:

1. Schematic Capture

Use EDA tools (e.g., KiCad, Eagle) to draft the circuit.
Assign footprints to components, prioritizing through-hole parts for single-sided compatibility.

2. Component Placement

Arrange components to minimize trace crossovers.
Place critical components (e.g., connectors, power regulators) near board edges.
Group related components (e.g., decoupling capacitors near ICs).

3. Routing Strategy

Route traces on the copper layer using horizontal/vertical grids to avoid overlaps.
Use jumpers or 0Ω resistors for unavoidable crossovers.
Maintain ≥0.3mm trace width for signals, ≥1mm for power lines.
Avoid sharp 90° angles; use 45° bends.

4. Power/Ground Planes

Create copper pours for GND, ensuring thermal reliefs for through-hole pads.
Isolate analog/digital grounds if needed.

5. Design Rule Check (DRC)

Set clearance rules (e.g., 0.2mm trace-to-pad, 1mm trace-to-board edge).
Run DRC to fix violations (e.g., short circuits, insufficient spacing).

6. Gerber File Generation

Top Copper Layer (.gtl)
Solder Mask Layer (.gts)
Silkscreen Layer (.gto)
Board Outline (.gko)

7. Fabrication Preparation

Print the layout on transparency film (1:1 scale) for UV exposure.
Cut copper-clad board to size, clean with steel wool.

8. Final Inspection

Check for broken traces, misaligned holes, or residual copper.
Test continuity and isolation with a multimeter.

How to Design A Single Sided Copper Clad PCB?

How to Make A Single Sided Copper Clad PCB Board?

Single-Sided Copper Clad PCB Production Process

1. Material Cutting

Cut large copper-clad panels into production-sized boards, optimizing material utilization.

2. Drilling

Machine holes for components and alignment using CNC drills. Laser drilling may be used for high-density boards.

3. Image Transfer

Dry Film Method: Apply photosensitive dry film, expose to UV light through artwork, and develop to form etch-resistant patterns.
Screen Printing: Directly print anti-etch ink, cured to create protective layers.

4. Etching

Remove uncovered copper using ferric chloride or ammonia-based etchants. Precision control of etchant concentration, temperature, and spray pressure is critical to minimize undercutting.

5. Stripping & Cleaning

Strip residual dry film/ink and rinse boards thoroughly. Dry boards to prevent oxidation.

6. Solder Mask & Marking

Solder Resist: Print green (or colored) solder mask, UV-cured to protect non-soldering areas.
Silkscreen: Print white legends for component identification and polarity marks.

7. Surface Finish

Apply finishes like HASL (spray tin), ENIG (chemical nickel/gold), or OSP (organic solderability preservative) to protect pads and enhance solderability.

8. Profiling

Shape boards via CNC routing or V-scoring for easy separation.

9. Inspection & Testing

Electrical Testing: Fly-probe or bed-of-nails testing for conductivity and insulation.
Visual Inspection: AOI (Automated Optical Inspection) or manual checks for defects (shorts, opens, misalignment).

10. Packaging

Vacuum-seal boards with desiccant and include quality certificates.

Why Choose Best Technology as Copper Clad PCB Manufacturer?

Reasons why choose us as copper clad PCB manufacturer:

Certified Compliance (ISO 9001, UL, RoHS, ISO 9001, IATF 16949 ): Mitigates regulatory risks and ensures products meet global standards for safety and environmental compliance.
Rapid Prototyping Service: 24-hour turnaround for samples with same-day engineering review.
Competitive Pricing Structure: Transparent pricing with no hidden fees—cost-effective for high-volume production.
Free DFM (Design for Manufacturability) Analysis: Optimizes PCB layouts to reduce material waste, lower production costs, and avoid late-stage design revisions.
Turnkey Solutions – Full-service PCB manufacturing from design to delivery, accelerating your product’s time-to-market.
Strict Quality Control: 100% automated optical inspection (AOI) and X-ray testing for defect-free PCBs.
Fast Production Lead Times: 15-day standard lead time with expedited options for urgent orders.
Custom Material Solutions: Tailored dielectric formulations for specific thermal/electrical requirements.
Dedicated Engineering Support: 24/7 technical team for design optimization and troubleshooting.

Why Choose Best Technology as Copper Clad PCB Manufacturer?

Our Copper Clad PCB Board Capabilities

Base material:	Copper
Thermal Conductivity (dielectric layer):	0.8, 1.0, 1.5, 2.0, 3.0 W/m.K.
Board Thickness:	0.5mm~3.0mm(0.02″~0.12″)
Copper thickness:	0.5 OZ, 1.0 OZ, 2.0 OZ, 3.0 OZ, up to 10 OZ
Outline:	Routing, punching, V-Cut
Soldermask:	White/Black/Blue/Green/Red Oil
Legend/Silkscreen Color:	Black/White
Surface finishing:	Immersion Gold, HASL, OSP
Max Panel size:	600500mm (23.62″19.68″)
Packing:	Vacuum/Plastic bag
Samples L/T:	4~6 Days
MP L/T:	5~7 Days

How to Get A Quote For Your Metal Core PCB Project?

Essential Submission Checklist

Design Files: Gerber layers, drill data (Excellon), assembly drawing.
Specs: Base material (aluminum/copper), core thickness (0.5–3.2mm), copper weight (1–4oz).
Electrical Needs: Max current (A/mm²), impedance control (±5%), via type.
Surface Finish: HASL, ENIG, or OSP.
Quantity & Deadline: Prototype (1–10 pcs) or mass production (>100 pcs), standard (15 days) or expedited (7 days).

Why Choose Best Technology?

Free DFM Review: Optimize designs for cost and manufacturability.
Instant Pricing: Quote within one day.
Certified Quality: IPC-A-600, UL, and RoHS compliance.

Email sales@bestpcbs.com with your specs for a fast, transparent quote. Let Best Technology’s metal core PCB expertise power your innovation!

Tags: Single Sided Copper Clad PCB, Single Sided Copper PCB
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What is Aluminium Based PCB? Aluminum PCB vs. FR-4

July 30th, 2025

An aluminium based PCB is a powerful choice for modern electronics, especially where heat control matters. Whether you’re designing LED lights, power supplies, or automotive electronics, aluminium PCBs help you manage temperature, protect components, and deliver stable performance. Compared to standard boards, they offer better heat dissipation, which can make a big difference in product reliability.

At Best Technology, we manufacture high-quality aluminium PCBs using certified materials and advanced processes. With certifications like ISO9001, ISO13485 for medical devices, IATF16949 for automotive, and UL approval, we provide dependable circuit boards tailored to your needs.

Aluminium Based PCB Manufacturer

What Is Aluminium PCB?

An aluminium PCB—also called a metal core PCB (MCPCB)—is a type of printed circuit board that uses aluminium as the base material instead of the common fiberglass material (FR-4). The board consists of three main layers:

Aluminium base layer for strength and heat conduction
Insulating dielectric layer to separate the metal from the copper
Copper circuit layer for electrical connections

This structure helps draw heat away from heat-sensitive components like LEDs, transistors, or power devices. In simple terms, aluminium PCBs help keep things cool, especially in high-power or high-temperature applications.

What Are the Pros and Cons of Aluminum PCB?

Aluminium-based PCBs are made from low-alloy Al-Mg-Si series high-plasticity aluminium plates (structure shown in the figure below). These boards offer excellent thermal conductivity, electrical insulation, and machinability. Compared to traditional FR-4 boards, aluminium PCBs of the same thickness and trace width can carry higher current. They also feature dielectric breakdown strength up to 4500V and a thermal conductivity greater than 2.0 W/m·K. In the PCB industry, aluminium-based boards are the most widely used metal core PCBs. Key advantages include:

Support for Surface Mount Technology (SMT)
Highly efficient thermal diffusion in circuit design
Lower operating temperature, higher power density, high reliability, and longer product lifespan
Smaller product size, reducing both hardware and assembly costs
Replacement for fragile ceramic substrates, offering better mechanical durability

But they also have some limitations:

Lower flexibility: Aluminium boards cannot be bent like flexible PCBs.
More complex manufacturing: Special processes are needed to drill and etch metal-based boards.
Limited layers: Multi-layer aluminium PCBs exist, but they are harder and more expensive to produce.

At Best Technology, we help customers balance these factors. Our engineering team guides you through design and material selection to ensure your aluminium PCB works perfectly for your application.

Aluminium PCB Material Properties

Aluminium based PCB typically made from aluminium alloys like 5052, 6061, or 3003. These materials are chosen to handle heat well, maintain electrical insulation, and provide mechanical support. Some customers may confused about them and the differences between these materials. Here Best Technology listing the properties of each material, hope this can help you to choose which one is best for your project.

Property	5052 Aluminium	6061 Aluminium	3003 Aluminium
Composition	Al-Mg alloy	Al-Mg-Si alloy	Al-Mn alloy
Thermal Conductivity	~138 W/m·K	~167 W/m·K	~160 W/m·K
Electrical Conductivity	~35% IACS	~40% IACS	~40% IACS
Tensile Strength	210–230 MPa	260–310 MPa	130–180 MPa
Yield Strength	~130 MPa	~240 MPa	~115 MPa
Elongation	~12–20%	~8–10%	~10–20%
Corrosion Resistance	Excellent	Good	Very Good
Formability	Excellent	Good	Excellent
Machinability	Fair	Good	Fair
Cost	Moderate	Higher	Lower
Common Use in PCBs	LED lighting, power electronics	High-power, structural applications	Consumer electronics, general use

Quick Notes:

5052 is favored for excellent corrosion resistance and good thermal performance, often used in outdoor lighting PCBs or marine applications.
6061 offers better strength and machinability, suitable for mechanically demanding PCBs or large-size boards.
3003 is cost-effective with good thermal and corrosion resistance, ideal for low to moderate power electronic boards.

How Thick Is Aluminum PCB?

Aluminium PCBs vary in thickness based on design and applications needs. Common thicknesses range from 0.8mm to 3.2mm, but custom options are available. Here is a standard aluminium PCB thickness rules:

Single-layer boards: Typically range from 0.2mm to 0.5mm, suitable for simple circuit designs.
Double-layer boards: Generally 0.5mm to 1.2mm, balancing both signal transmission and heat dissipation needs.
Multi-layer boards: Thickness starts from 1.2mm and can reach up to 10mm, ideal for high-power electronic devices.

For applications with high thermal conductivity requirements (such as LED lighting and power electronics), aluminium PCBs may use thinner copper foil (ranging from 35μm to 280μm) laminated with the aluminium base. In such cases, the minimum board thickness can be as low as 0.075mm.

At Best Technology, we help customers choose the right thickness based on current flow, heat output, and mechanical strength. Thicker boards may cost more but offer better performance in demanding settings.

What is Aluminium Based PCB? Aluminum PCB vs. FR-4

What Is the Maximum Temperature for Aluminium PCB?

Aluminium PCBs are built for high-temperature conditions. The dielectric layer determines the maximum working temperature, which typically ranges between 130°C to 150°C. Special materials can go higher, depending on the design.

Why is this important? In LED lighting or automotive power modules, excess heat can damage components. By using aluminium PCBs, you keep the temperature down and extend the life of your product. If you want to used in extreme high temperature applications, we have ceramic PCB that can achieve 850°C.

Aluminium PCB Manufacturing Process – Simplified

1. Material preparation: Select the right aluminium base, apply dielectric material, and add copper foil.

2. Drilling: CNC machines create holes for vias and component placement.

3. Circuit imaging: A photoresist is applied, and UV light is used to define the circuit pattern.

4. Etching: Unwanted copper is removed, leaving only the desired circuit.

5. Plating: Through-hole plating may be used if needed for connections.

6. Solder mask application: A protective layer prevents oxidation and solder bridging.

7. Surface finish: Common finishes include ENIG (Electroless Nickel Immersion Gold), HASL (Hot Air Solder Leveling), or OSP (Organic Solderability Preservative).

8. Testing: Electrical and thermal tests ensure each board performs as required.

Below is the detailed aluminium based PCB manufacturing process. Best Technology uses advanced MES systems for full traceability and tight quality control. We support both prototype runs and mass production with fast turnaround times.

How Does an Aluminium Based PCB Cost?

Several factors influence the cost of aluminium PCBs:

Material grade: Higher-quality aluminium and thermal materials cost more.
Board size and complexity: Larger boards or intricate designs increase price.
Copper thickness: Thicker copper adds to material and processing costs.
Surface finish: ENIG is more expensive than HASL or OSP.
Quantity: Bulk orders lower per-unit costs.

In general, aluminium PCBs cost more than FR-4 for simple designs but offer cost savings in thermal management. For example, using aluminium boards can eliminate the need for extra heat sinks or cooling fans. At Best Technology, we offer competitive pricing and help you optimize design for cost and performance.

What Is the Difference Between Aluminum PCB and FR-4?

The main difference between aluminum PCBs and FR-4 PCBs lies in the base material and how each board handles heat and mechanical stress.

Aluminum PCBs use a metal base (usually aluminum) that helps conduct heat away from components. This makes them a great choice for high-power circuits like LEDs and power supplies. In contrast, FR-4 PCBs are made from fiberglass material. They are versatile and cost-effective but have poor thermal conductivity, which can be a problem in heat-sensitive designs. Here’s a quick side-by-side comparison:

Feature	Aluminum PCB	FR-4 PCB
Base Material	Aluminum (metal core)	Fiberglass (FR-4)
Thermal Conductivity	High (1.0–3.0 W/m·K)	Low (~0.3 W/m·K)
Heat Dissipation	Excellent	Limited
Strength	Strong and durable	Moderate
Flexibility	Low (rigid)	Higher (can be rigid or flexible)
Cost	Slightly higher (for materials)	Lower for basic designs
Typical Use	LEDs, power electronics, automotive	Consumer electronics, general use

Use aluminium PCBs when your design needs to handle heat efficiently and survive tough environments. Use FR-4 when thermal demands are low, or you need flexible or multi-layer boards.

When to Use Aluminum PCB?

Aluminium PCBs are the right choice when you need:

Efficient heat dissipation
Reliable performance in high-power applications
Space-saving designs without extra heat sinks

Common applications include:

LED lighting systems (e.g., streetlights, automotive lamps)
Power converters and inverters
Battery chargers
Audio amplifiers
Telecom and base stations

If your design struggles with overheating or if your product needs to run 24/7 without failure, aluminium PCBs can help you achieve that.

At Best Technology, we specialize in custom aluminium PCBs with strict quality standards and professional support. Whether you need single-layer, multi-layer, or special-shaped boards, we’ve got you covered. Ready to explore aluminium PCB solutions? Contact Best Technology today for a quote or technical consultation.

FAQs

1. Can aluminium PCBs be used in flexible applications?

No, aluminium PCBs are rigid. If you need flexibility, consider flexible PCBs or hybrid designs.

2. Are aluminium PCBs more expensive than FR-4?

Yes, but they reduce the need for additional cooling, saving costs in the long run.

3. Can I use aluminium PCBs for RF applications?

Yes, with the right dielectric material, aluminium PCBs can work in RF circuits.

4. How fast can I get aluminium PCBs from Best Technology?

We offer fast lead times, depending on design and quantity. Contact us for details.

5. Do you provide samples for testing?

Yes, we support prototype orders to help you test and finalize your design.

Tags: aluminium based pcb, aluminium based pcb cost, aluminum pcb vs fr4
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