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What is Copper Busbar? PCB Copper Busbar Manufacturers​
Tuesday, August 19th, 2025

Are you worried about these issues?

  • Is copper busbar overheating in high-current applications, causing efficiency drops or even system shutdowns?
  • Is corrosion or oxidation in humid or harsh environments leading to frequent maintenance?
  • Do you need flexible copper busbar customization to fit different battery modules or inverter layouts?

Best Technology provides tailored copper busbar solutions that balance cost, performance, and flexibility. We offer:

  • Competitive pricing directly from manufacturer
  • Customized sizes, coatings, and shapes
  • High durability = long-term cost savings
  • No minimum order quantity requirements, I pcs prototype order is available

If you are comparing copper busbar manufacturers or exploring advanced copper busbar PCB designs, Best Technology can help. With certifications including ISO9001, ISO13485, IATF16949, and AS9100D, we maintain strict quality control from raw material to finished product. Our MES system keeps every component traceable, while competitive copper busbar price and flexible engineering support bring added value.

Whether you need standard copper busbar, custom busbar copper shapes, or integrated PCB busbar solutions, Best Technology offers expertise and reliability in every project. If you are interested in copper busbar or copper busbar pcb, welcome to contact us at sales@bestpcbs.com.

What is Copper Busbar?

A copper busbar is a flat strip, rod, or bar of copper designed to conduct electricity. Unlike flexible wires, it’s rigid, strong, and tailored to carry heavy current loads. You’ll often find it inside switchgear cabinets, power distribution panels, and large battery packs.

Why copper? Because copper has excellent conductivity and thermal performance. It carries more current per square millimeter than most other metals while staying stable over long service periods. For engineers, this means reduced energy losses and fewer overheating issues.

In short, copper busbar is the highway for electricity inside modern systems.

What is Copper Busbar? PCB Copper Busbar Manufacturers​

What is Copper Busbar?

Why is it Called a Busbar?

The word “bus” in electrical engineering describes something that collects and distributes. Just as a city bus gathers passengers and delivers them to different stops, a busbar gathers current from various circuits and spreads it across the system.

The “bar” part is literal—it’s a bar of conductive material. Together, the term “busbar” reflects its function and shape. Over decades, this word became standard, and now it’s used across industries worldwide.

How to Make a Copper Busbar?

The process of making busbar copper combines precision with material science. Here’s how manufacturers typically approach it:

1. Copper Selection – Most copper busbar manufacturers choose high-conductivity grades such as ETP (Electrolytic Tough Pitch) or OFHC (Oxygen-Free High Conductivity). These ensure stable performance.

2. Cutting and Shaping – Large copper sheets are cut into required sizes. CNC punches and hydraulic presses shape the bar with consistent accuracy.

3. Drilling and Punching – Holes and slots are added for bolted connections. This step requires exact tolerances so that joints stay secure.

4. Bending – Depending on installation needs, busbars are bent into L, U, or Z shapes without compromising mechanical strength.

5. Surface Finishing – To prevent oxidation, surfaces may be tin-plated, silver-plated, or coated with nickel. This not only protects but also improves contact reliability.

6. Insulation (Optional) – In compact systems, epoxy coatings or heat-shrink sleeves are added to prevent accidental shorts.

How to Make a Copper Busbar?

Every step is controlled to deliver high current capacity while keeping mechanical stability intact.

How to Clean Copper Busbar?

Over time, copper busbar surfaces can tarnish. A thin oxide layer forms, which slightly increases resistance. Cleaning restores performance. Here are some practical methods:

  • Mechanical cleaning – Sandpaper, wire brushes, or abrasive pads can remove the oxidation layer.
  • Chemical cleaning – Mild acidic solutions like vinegar mixed with salt, or commercial copper cleaners, dissolve corrosion without damaging the base metal.
  • Protective treatment – After cleaning, applying a thin coat of petroleum jelly or anti-oxidation grease helps slow down further tarnish.

Routine cleaning is important in high-current systems, as even small resistance increases can generate heat under load.

How to Calculate Copper Busbar Size?

Choosing the right copper busbar size means balancing current capacity with safety. Engineers often use a current density rule to determine cross-sectional area.

The common design range is 1.2 to 1.6 A per square millimeter of copper in open air.

Formula:

For example, a busbar that needs to carry 800A at 1.5 A/mm² should have at least:

If designed as 40 mm wide and 14 mm thick, this cross-section provides adequate capacity. Designers then check thermal rise and cooling conditions to finalize the dimension.

Copper Busbar vs Copper Busbar PCB

Although both serve as conductors, there are differences between traditional copper busbar and copper busbar PCB:

  • Copper Busbar – A standalone strip or bar. Common in switchgear, transformers, and large distribution panels.
  • Copper Busbar PCB – A printed circuit board reinforced with very thick copper layers or embedded copper strips. Used in compact high-power electronics such as EV inverters.

The advantage of copper busbar PCB is space efficiency. Instead of bulky bars and cables, the PCB integrates power and signal layers together, simplifying assembly.

Copper Busbar vs Copper Busbar PCB

Busbar Copper PCB

Why Choose Copper Busbar PCB?

Copper busbar PCB, sometimes called embedded busbar PCB or busbar-integrated PCB, is a smart evolution of traditional busbars. In some industries, it is also referred to as reinforced thick copper PCB, since the board integrates additional copper bars or strips inside or on the surface to handle heavy current.

The reason many designers choose copper busbar PCB over standalone busbars lies in its unique advantages:

  • Compact design – Instead of bulky copper bars and multiple cables, busbar copper is embedded in the PCB, reducing space requirements.
  • Improved thermal balance – Heat spreads evenly across the board, preventing local hotspots in high-power circuits.
  • Simplified assembly – Fewer mechanical joints mean lower installation time and reduced risk of loose connections.
  • Cost efficiency – By combining signal and power layers in one PCB, manufacturers save both material and labor cost.
  • Reliability – With laminated structure and less mechanical stress, copper busbar PCB performs well even in vibration-heavy environments such as automotive or industrial drives.
Why Choose Copper Busbar PCB?

Copper Busbar Size and Current Rating Table

Here’s a general table showing copper busbar size with approximate current ratings (open air, 35°C rise). Values vary depending on installation and cooling.

Thickness (mm)Width (mm)Max Current (A)Typical Applications
11050Small electronics
220150Industrial control
325250Switchboards
550500EV battery modules
101001200Power distribution systems

These values are approximate. Always confirm with copper busbar manufacturers for precise specifications based on your operating environment.

How Much Does a Copper Busbar of Length 40 cm Carry?

The capacity depends mainly on cross-section, not just length.

  • A 20 × 5 mm busbar of 40 cm can carry about 160–200A.
  • A 40 × 10 mm busbar of the same length can handle up to 700A.

Length matters for voltage drop, but current capacity is almost entirely governed by cross-section and cooling.

Why Copper Busbar is Suitable for Electric Vehicles?

Electric vehicles place extreme demands on conductors. High current during acceleration, fast charging, and compact layouts require components that can cope with stress. Copper busbar delivers in several ways:

  • Efficient conduction – Copper reduces resistive loss, extending driving range.
  • Thermal control – With high conductivity, copper disperses heat effectively during charging cycles.
  • Space saving – Laminated copper busbars replace bundles of cables, reducing weight and assembly time.
  • Durability – Resistant to vibration and mechanical wear, critical for vehicles exposed to constant motion.

That’s why most EV battery packs and controllers today rely heavily on laminated busbar copper.

What is a Copper Busbar PCB Used For?

  • Power electronics – Converters, inverters, and rectifiers.
  • Automotive – EV drive systems, on-board chargers, and battery management units.
  • Renewable energy – Solar string inverters and wind turbine controllers.
  • Industrial systems – Robotics, automation drives, and motor controllers.

FAQs

Q1: What makes copper busbar better than aluminum busbar?

Copper has higher conductivity and better mechanical durability, leading to improved performance and longer service life.

Q2: Can copper busbar be customized?

Yes. Width, thickness, plating, and hole punching can all be tailored to specific installations.

Q3: What is the Copper Busbar HS Code?

Most copper busbars fall under HS Code 7407, covering copper bars and profiles.

Q4: What drives copper busbar price?

Mainly copper market fluctuations, plus cost of processing and plating.

Q5: Is copper busbar PCB the same as heavy copper PCB?

It is a type of heavy copper PCB, but they have several differences. Heavy copper PCB only increases copper layer thickness, while copper busbar PCB embeds solid busbars for even higher current handling.

This is the end of this blog, if you have any other questions about copper busbar pcb, you are welcome to contact our team, our sales are always online!

What is ICT Tester? In Circuit Test vs Flying Probe Testing
Monday, August 18th, 2025

Have you ever wondered why some electronic devices fail even when the PCB looks flawless? Or why high-volume production sometimes delivers inconsistent boards? These issues often trace back to undetected component defects, poor soldering, or faulty connections. Without proper testing, even a single defective part can lead to product failure, costly recalls, or customer dissatisfaction.

This is where an ICT tester equipment comes in. By performing in-circuit testing (ICT), manufacturers can quickly detect missing components, shorts, opens, and incorrect placements before the boards leave the production line. With the right ICT test electronics and in-circuit test fixtures, you gain fast, accurate, and reliable validation of each PCB, saving both time and money.

In this article, we’ll answer key questions such as:

  • What exactly is an ICT tester, and how does it work?
  • Why is ICT testing so critical for electronics manufacturing?
  • How does ICT differ from functional testing or flying probe testing?
  • When should you use ICT versus functional testing for your boards?

By understanding these points, you’ll see how ICT testing can prevent defects, improve production efficiency, and ensure reliable end products—turning potential headaches into controlled, predictable outcomes.

What is an ICT Tester?

An ICT tester is a system designed to perform in-circuit testing (ICT) on printed circuit boards after assembly. It is often recognized by its “bed-of-nails” fixture, which has hundreds or even thousands of pins arranged to contact specific points on the PCB. Each pin corresponds to a pad, via, or test point, allowing the tester to measure voltages, resistances, and currents at component level.

ICT testers can:

  • Detect missing, incorrect, or faulty components.
  • Identify open circuits, short circuits, and soldering defects.
  • Measure parameters such as resistance, capacitance, and diode orientation.
  • Verify integrated circuit placement and connectivity.

Because ICT is thorough and fast, it has become an industry-standard approach, especially in high-volume production lines.

Why is the ICT Test Important?

The ICT test is important for several reasons. In large-scale manufacturing, even a single defect can ripple into thousands of defective units. Detecting issues early reduces costs, avoids recalls, and protects brand reputation.

For example, in automotive electronics, where safety systems depend on flawless PCBs, ICT is crucial. An undetected fault in an airbag control system could have serious consequences. In consumer electronics, ICT prevents faulty smartphones, laptops, or home appliances from reaching the market.

The ICT test is also important for process improvement. It provides engineers with statistical data that highlights recurring problems, such as solder bridging or component misplacement. Manufacturers can use this data to refine processes, reduce defect rates, and improve yields.

What is the Purpose of the ICT Test?

The main purpose of ICT testing is to validate the quality and functionality of each component on the PCB. Unlike functional testing, which looks at the board’s overall behavior, ICT digs into details at component level.

ICT ensures that:

  • Every resistor has the correct value.
  • Capacitors and inductors are present and within tolerance.
  • Diodes and transistors are oriented properly.
  • Integrated circuits are placed in the right sockets and connected.

By catching defects at the source, ICT reduces the risk of failures at the product’s final stage. This is especially valuable in industries where long-term reliability is critical, such as aerospace, defense, and medical devices.

How Does an ICT Tester Work?

An ICT tester works by pressing the in-circuit test fixture against the PCB, making contact with the test pads or vias. Once contact is established, the system injects signals into the board and records the response.

Here’s a breakdown of the process:

  • Fixture Setup – The board is placed into a bed-of-nails fixture designed for its exact layout.
  • Signal Injection – Test probes inject electrical signals into various nodes of the circuit.
  • Measurement – The tester measures voltage, current, resistance, and capacitance at each point.
  • Analysis – Software compares the measured values with predefined thresholds.
  • Reporting – The system highlights any failures or deviations for quick troubleshooting.

ICT is highly automated, with a cycle time ranging from a few seconds to less than a minute. This makes it efficient for high-volume production, where time savings directly translate to lower manufacturing costs.

Advantages of ICT Testing

  • High Accuracy – Detects even subtle component defects.
  • Fast Cycle Time – Ideal for mass production.
  • Detailed Data – Provides insight into manufacturing trends.
  • Early Detection – Reduces rework and repair costs.
  • Reliability – Improves long-term performance of products.

What is the Difference Between Functional Testing and ICT Testing?

Both functional testing and ICT testing play important roles in quality assurance, but they target different aspects of the PCB.

  • ICT Testing – Focuses on component-level verification. It checks each resistor, capacitor, diode, transistor, and IC independently. ICT identifies defects like shorts, opens, wrong components, or poor solder joints.
  • Functional Testing – Evaluates the overall system behavior. It simulates real-world operating conditions, ensuring the PCB performs its intended function. Functional testing may involve powering up the device, running software, or checking communication protocols.

To put it simply: ICT looks at how the board is built, while functional testing checks how the board behaves. Both tests are complementary, and many manufacturers use them together.

Functional Testing vs ICT Testing

When to Use ICT and Functional Testing?

Choosing between ICT and functional testing depends on project goals and production stage.

Use ICT testing when:

  • Boards are still in the manufacturing phase.
  • Component-level accuracy needs to be validated.
  • High-volume production demands fast, repeatable results.

Use functional testing when:

  • The assembly is nearly complete.
  • The product’s performance under real operating conditions needs to be verified.
  • System-level testing is required, such as communication between multiple boards.

For best results, many manufacturers use a combination of ICT and functional testing. ICT catches early-stage defects, while functional testing provides final validation before shipment.

In-Circuit Test vs Flying Probe: What are Differences?

When comparing in-circuit testing (ICT) with flying probe testing, the differences come down to cost, speed, and flexibility.

In-Circuit Test (ICT):

  • Uses a custom in-circuit test fixture.
  • Offers fast cycle times (seconds).
  • Best for high-volume production.
  • High upfront cost for the fixture, but lower cost per test afterward.

Flying Probe Test:

  • Uses moving probes instead of a fixture.
  • Slower than ICT, since probes move sequentially.
  • Excellent for prototypes and low-volume runs.
  • No fixture cost, making it more flexible and cost-effective for small batches.

In practice, many manufacturers start with flying probe testing during prototyping. Once the design is finalized and volumes increase, they shift to ICT testing for efficiency.

In-Circuit Test vs Flying Probe

Applications of ICT Testing

ICT testing is used in a wide range of industries:

  • Automotive – For safety-critical systems like airbags, ABS, and engine control units.
  • Medical Devices – For life-support systems, imaging equipment, and diagnostic tools.
  • Aerospace and Defense – Where reliability under extreme conditions is non-negotiable.
  • Consumer Electronics – From smartphones to laptops, ensuring consistent quality.
  • Industrial Equipment – For automation controllers and power management systems.

In each of these cases, ICT contributes to higher reliability, lower failure rates, and better compliance with international standards.

Why Choose Best Technology for ICT and PCB Testing?

Best Technology is a reliable PCB manufacturer in China, trusted by more than 1,000 customers across industries worldwide. We specialize in small to medium-volume PCB manufacturing, PCB assembly, and complete electronic manufacturing services.

As one of the most experienced circuit board suppliers, our capabilities cover a wide range of PCB types, including rigid PCBs, flex PCBs, rigid-flex PCBs, aluminum PCBs, RF/microwave PCBs, high-speed and high-frequency PCBs, and HDI PCBs. Beyond manufacturing, we also provide turnkey assembly, component sourcing, box build assembly, PCBA testing, and full electronic testing services.

With over 19 years of experience, our engineering, production, and quality teams fully understand the unique needs of industries such as medical, automotive, and aerospace. We strictly follow international standards, working under IPC-A-600 for PCB manufacturing and IPC-A-610 for PCB assembly. All of our products meet IPC Class 2 standards, and for projects requiring higher reliability, we also deliver Class 3 or Class 3A compliance. Combined with strong engineering support and competitive pricing, we help customers achieve both reliability and cost-effectiveness.

FAQs

1. What does ICT stand for in electronics testing?

ICT stands for in-circuit testing, which validates the quality of individual PCB components.

2. Can ICT testing replace functional testing?

No. ICT and functional testing serve different purposes. ICT checks construction, while functional testing checks performance.

3. How long does an ICT test take?

Most ICT tests take only a few seconds, depending on the number of test points.

4. Is an in-circuit test fixture reusable?

Yes, but each fixture is custom-designed for a specific PCB layout.

5. Which is better: in-circuit test or flying probe?

ICT is best for high-volume runs due to speed. Flying probe is better for prototypes or small batches.

IPC 610 Certification​: Class I vs. Class II vs. Class III
Thursday, August 7th, 2025

If you’re working in electronics manufacturing or sourcing PCB assembly services, you’ve likely come across the term IPC 610. This standard, also known as IPC-A-610, plays a major role in ensuring the quality and reliability of electronic assemblies. Whether you’re dealing with consumer gadgets or mission-critical aerospace systems, understanding IPC-A-610 can help you make better decisions and achieve higher quality outcomes.

Let’s explore what IPC-A-610 is all about, how it classifies assemblies, and why choosing a PCB manufacturer certified with IPC-A-610 can make a real difference.

What is IPC-A-610 Standard?

IPC-A-610 is a globally recognized standard for the acceptability of electronic assemblies, developed by the IPC. It sets the inspection criteria for electronic assemblies, particularly focusing on how solder joints and components should appear on the finished board.

This standard acts as a visual guide for manufacturers, inspectors, and engineers to determine whether a PCB assembly meets quality expectations. It defines what’s acceptable and what’s not, ensuring that defects are minimized and performance isn’t compromised. The most recent version is IPC-A-610H, though previous versions like IPC-A-610F and IPC-A-610G are still in use in some industries.

IPC 610 Certification

What Are the Classes in IPC-A-610?

IPC-A-610 breaks down its quality requirements into three distinct classes. These classes define the level of workmanship needed based on the end-use of the product.

  • Class I – General Electronic Products
  • Class II – Dedicated Service Electronic Products
  • Class III – High-Performance Electronic Products

IPC-A-610 Class I vs Class II vs Class III

1. Class I – General Electronic Products

Class I represents the basic level of acceptability for electronic assemblies. Products in this category are designed for simple, everyday use, where the main concern is that the device works—not how it looks or how long it lasts.

Key Features of Class I:

  • Function over form: As long as the product performs its basic function, it’s considered acceptable—even if it has minor cosmetic defects.
  • Loosest inspection standards: Imperfections like uneven solder or slight misalignment may be allowed if they don’t impact performance.
  • Minimal cost and time: Because of the relaxed standards, Class I products are faster and cheaper to manufacture.

Typical Applications:

  • Toys
  • Flashlights
  • Basic household gadgets
  • Low-cost consumer electronics

2. Class II – Dedicated Service Electronic Products

Class II is the most commonly used class in electronics manufacturing. It sets moderate quality standards suitable for products that require reliable performance over time, but where minor cosmetic issues are acceptable.

Key Features of Class II:

  • Performance and lifespan: Devices are expected to work reliably under normal conditions for their intended lifespan.
  • Stricter inspection than Class I: Components must be correctly placed, and solder joints must be solid, though slight cosmetic flaws may still be allowed.
  • Balance of quality and cost: This class strikes a practical balance between reliability and manufacturing efficiency.

Typical Applications:

  • Industrial control systems
  • Consumer electronics (TVs, laptops, phones)
  • Automotive electronics (non-safety critical systems)
  • Networking devices (routers, modems)

3. Class III – High-Performance Electronic Products

Class III is for products that require the highest level of quality and reliability. These are mission-critical applications where even a minor defect could lead to system failure, safety risks, or major financial loss.

Key Features of Class III:

  • No room for error: Every solder joint, component placement, and surface must meet strict inspection criteria with no cosmetic imperfections allowed.
  • Extended reliability and lifespan: Products must perform flawlessly in harsh environments, under continuous use or critical conditions.
  • Higher cost and longer production: The level of detail and inspection required increases both time and production cost.

Typical Applications:

  • Medical devices (life-support systems, diagnostic equipment)
  • Military electronics (communication systems, radar)
  • Aerospace electronics (navigation, avionics)
  • Automotive safety systems (airbags, braking systems)

What Are Common PCB Defects Covered by IPC-A-610?

IPC-A-610 outlines many types of assembly defects, helping manufacturers inspect and correct issues before products reach customers. Some of the most common defects it covers include:

  • Cold solder joints – Dull, grainy joints that may lead to poor electrical contact.
  • Insufficient solder – Joints that don’t provide full coverage, risking weak connections.
  • Solder bridging – Excess solder creating unwanted connections between pads or leads.
  • Component misalignment – Parts not properly placed on pads, affecting function or reliability.
  • Contamination – Presence of dust, oils, or residue that could impact signal integrity or cause corrosion.
  • Lifted pads or traces – Damage to the PCB surface, which can break electrical paths.

Here are some commone defects that can be acceptted by IPC 610 Class I & Class II:

What Are Common PCB Defects Covered by IPC-A-610?

What is the Difference Between IPC-A-610 and IPC J-STD-001?

Many people confuse IPC-A-610 with another widely used standard — IPC J-STD-001. While they are related, they serve different purposes.

  • IPC-A-610 focuses on how the finished assembly should look. It is a visual inspection standard used to judge whether the product is acceptable.
  • IPC J-STD-001 sets the soldering process requirements. It guides manufacturers on how to achieve quality solder joints, covering materials, equipment, and techniques.

In short:

  • J-STD-001 = Process and workmanship standard
  • IPC-A-610 = Visual acceptance standard

Many manufacturers follow both standards together to ensure not only that the product looks correct but also that it was built using reliable processes.

One-Stop PCB Assembly Manufacturer Certified with IPC-A-610

When you need reliable PCB assembly, it pays to choose a manufacturer certified with IPC-A-610. At Best Technology, we follow strict IPC-A-610 Class II and Class III guidelines across our production lines.

Here’s what sets us apart:

  • Certified Inspectors and Assemblers

All staff involved in production and inspection are IPC-A-610 certified, ensuring every board meets required standards.

  • Full Traceability

We use MES (Manufacturing Execution System) to track every step, from incoming materials to final inspection. This guarantees complete traceability and quality control.

  • Serving Demanding Industries

Our IPC-compliant services are trusted in automotive, medical, industrial, and aerospace sectors.

  • Competitive Pricing and Fast Turnaround

With advanced equipment and a professional engineering team, we provide fast, affordable, and reliable PCB assembly services.

Whether you need small-batch prototypes or large-volume production, Best Technology ensures your PCBs meet IPC-A-610 standards, giving you peace of mind with every shipment.

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

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

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

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

What Does Exposed Copper on PCB Mean?

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

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

Where Is Copper Usually Exposed?

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

Purpose of Designing Exposed Copper on PCB

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

1. Electrical Contact

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

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

2. Thermal Management

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

3. Grounding and Shielding

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

4. Cost Considerations

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

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

Types of Exposed Copper PCB Designs

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

1. Exposed Copper Pads

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

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

2. Exposed Copper Traces

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

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

3. PCB Exposed Copper Edge

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

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

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

What Is the Clearance of Copper to Edge of PCB?

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

Industry Guidelines

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

Edge Copper Design

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

How to Design a PCB with an Exposed Copper Plate?

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

Step 1: Define Copper Areas

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

Step 2: Disable Solder Mask

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

Step 3: Edge Exposure

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

Step 4: Selective Surface Finish

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

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

Risks and Challenges with Exposed Copper PCB

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

Oxidation and Corrosion

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

Short Circuits

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

Handling Risks

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

Exposed Copper Design Guidelines in PCB Layout

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

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

FAQs

1. How to remove copper from PCB board?

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

2. What happens to exposed copper?

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

3. Can exposed copper PCB be used outdoors?

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

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

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

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

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

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

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

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

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

What is Cu Inlay PCB? Copper Inlay PCB Market
Thursday, July 31st, 2025

A Cu inlay PCB, also called copper inlay PCB or bus bar PCB, is designed to manage high current flow and heat dissipation in modern electronic systems. As electronic devices become more compact and powerful, the need for better power handling within limited space grows rapidly. Standard copper traces often can’t handle high current without overheating or losing efficiency. That’s where copper inlay PCBs offer a smart and effective solution.

At Best Technology, we specialize in custom copper inlay PCBs, supporting demanding industries like automotive, industrial control, and renewable energy. We use advanced techniques to embed copper bars directly into PCBs, helping your products perform better and last longer.

What Is Cu Inlay PCB?

A Cu inlay PCB is a circuit board where solid copper blocks or bars are inserted into the board structure. These copper inlays are physically placed into slots or cutouts in the base material of the PCB, often FR4, aluminum, or other substrates.

The copper inlay becomes part of the circuit, connecting to surrounding copper traces and components. Instead of relying on thin copper layers, which might struggle with high current, thick copper inlays offer a low-resistance path for electricity and a direct route for heat dissipation.

These PCBs are sometimes known as bus bar PCBs because the inlay acts like a mini bus bar embedded inside the board. They are often found in designs where power density is high, and the space for external power routing is limited.

What is Cu Inlay PCB? Copper Inlay PCB Market

What Is the Working Principle of Inlay Copper in PCB?

In a copper inlay PCB, the working principle revolves around using solid copper bars to conduct electricity and transfer heat efficiently. Here’s how it works:

  • Precision Cutouts: During the PCB manufacturing process, slots or grooves are milled into the base material to fit the copper inlays.
  • Copper Insertion: A solid copper bar or block is placed into each slot, making it part of the board structure.
  • Electrical Connection: The inlay is then electrically connected to surrounding copper traces. This can be done via plated-through holes, soldering, or lamination, depending on the design.
  • Heat Transfer: When high current flows through the board, the copper inlay not only carries the current but also absorbs and spreads heat. This helps prevent overheating and improves the reliability of the entire system.

Because copper has high electrical and thermal conductivity, the inlay serves two purposes: reducing voltage loss and keeping temperatures low.

Why Inlay Copper in the PCB?

The main reason to use inlay copper in a PCB is to manage high current and heat in a compact space. In many power electronic devices, standard copper layers are too thin to carry heavy current without voltage drops or overheating. Here are key reasons to choose copper inlay PCB:

  • High Current Needs: When your design must carry more than 20-100 amps of current, copper inlays provide a path that minimizes power loss.
  • Thermal Control: Devices with power-hungry components, such as power MOSFETs, IGBTs, or coils, generate a lot of heat. Copper inlays help pull heat away from these hot spots.
  • Space Limitations: Using thick copper over the entire PCB increases cost and thickness. Copper inlay allows selective reinforcement, only where needed.
  • Improved Design Flexibility: Copper inlays can be designed into specific regions, enabling multi-zone current paths and optimized thermal management.

In short, inlay copper in PCB helps engineers create more reliable, efficient, and compact systems.

Benefits of Copper Inlay PCB

1. With a copper inlay, your PCB can safely carry high current levels (often over 100A) without the risk of burning or damage. The solid copper inlay has low resistance, which minimizes energy loss.

2. Copper inlays absorb heat from nearby components and transfer it efficiently to heat sinks or metal housings.

3. Instead of using bulky external bus bars or thick copper layers, copper inlays offer a space-saving option. They let you design smaller PCBs with higher performance, which is ideal for portable or space-constrained products.

4. The solid metal insert adds strength to the PCB structure. It prevents board bending or warping and supports heavy components mounted on top.

Copper Core PCB vs Copper Inlay PCB

Some engineers may wonder: should I choose copper core PCB or copper inlay PCB? Both types are designed to improve heat management and electrical performance, but they use different structures and serve different needs.

A copper core PCB is a type of metal core PCB, uses a solid copper plate as the base material. This copper core acts as a heat spreader, helping to quickly transfer heat away from the entire board. It is ideal for applications where even heat distribution is required across a large area.

In contrast, a copper inlay PCB typically uses FR4 or other insulating materials as the base, with copper bars inserted into machined slots only in selected areas. These copper inlays handle high current directly and provide localized thermal management exactly where it’s needed.

FeatureCopper Core PCBCopper Inlay PCB
Copper PlacementFull copper plate inside the PCBCopper bar inserted into slots
Heat ManagementUniform heat spread across the boardTargeted heat dissipation
Current HandlingGood, but may require thick PCBExcellent, at specific points
Flexibility in DesignLess flexible, fixed copper plateFlexible, inlays only where needed
CostHigher due to full copper layerMore cost-effective (selective use)

In summary, copper core PCBs are best for broad heat dissipation, while copper inlay PCBs are preferred when you need high current capacity in specific zones with better design flexibility and material savings.

Factors Affect Copper Inlay PCB Price

The price of copper inlay PCBs can vary widely based on your design needs, order volume, and technical requirements. Several factors directly affect the cost:

1. Copper Inlay Size and Thickness

    Larger and thicker copper bars increase both material and machining costs. Inlays typically range from 1mm to 5mm thick. Thicker copper costs more due to higher copper usage and longer machining time.

    2. Board Size and Layers

    Larger PCBs and multi-layer designs involve more material, labor, and processing steps, leading to higher costs.

    3. Surface Finishes and Testing

    Special surface finishes like ENIG, immersion silver, or selective gold plating, as well as full electrical or thermal testing, can add to the overall cost.

    4. Order Quantity

    Larger orders benefit from volume discounts, while small batches have higher unit prices due to setup and tooling time.

    5. Price Range

    For reference, the typical price range for copper inlay PCBs is approximately:

    • Prototype or low volume: $300 – $800 per square meter
    • Medium volume: $200 – $400 per square meter
    • Mass production: $100 – $250 per square meter

    Note: These are estimated ranges. Actual prices depend on copper inlay dimensions, layer count, complexity, and finish options.

     Cu Inlay PCB

    Applications of Inlay Copper PCB

    Copper inlay PCBs are found in various high-performance industries. They are ideal for power electronics, where current and thermal reliability are critical.

    Here are typical applications:

    • Electric Vehicles (EV): Power inverters, charging systems, battery control units.
    • Industrial Equipment: Motor drives, programmable logic controllers (PLCs), industrial inverters.
    • Renewable Energy Systems: Solar panel controllers, wind turbine systems, energy storage units.
    • Telecommunication: Base station power modules, signal amplifiers.
    • Medical Devices: MRI machines, laser equipment, diagnostic tools needing high power.
    • Aerospace: Avionics systems requiring compact, high-current PCBs.

    Wherever power density and space-saving are essential, copper inlay PCBs provide a robust solution.

    Copper Inlay PCB Market Trend

    The global copper inlay PCB market is experiencing steady growth. As industries demand higher efficiency and miniaturization, copper inlay PCBs are becoming a preferred solution.

    Key market trends include:

    • Rapid growth in electric vehicles, where compact power modules are essential.
    • Expansion in solar and wind energy sectors, requiring efficient power conversion.
    • Increased use of AI and 5G equipment, which needs reliable power systems.
    • Rising demand for high-performance PCBs in medical, defense, and aerospace applications.

    As a leading copper inlay PCB manufacturer, Best Technology continues to invest in production capacity, quality systems, and engineering services to meet this rising demand.

    Why Choose Best Technology for Your Copper Inlay PCBs?

    With over a decade of experience in advanced PCB manufacturing, Best Technology is a trusted partner for companies needing high-performance copper inlay PCBs. We’ve helped clients in automotive, industrial control, telecommunications, and energy sectors bring reliable products to market faster.

    1. We have extensive experience producing copper inlay PCBs with varied designs—from simple one-inlay boards to complex multi-inlay configurations.

    2. Our production lines feature state-of-the-art CNC milling equipment, automated plating systems, and tight-tolerance inspection tools.

    3. Our R&D team and senior engineers work directly with clients to optimize designs, suggest improvements, and solve complex challenges.

    4. With efficient production scheduling, MES-based traceability, and streamlined logistics, we deliver both prototypes and volume orders quickly.

    5. We are certificated with ISO9001, IATF16949, ISO13485, AS9100D systems.

    FAQs

    1. What is the typical thickness of copper inlays?

    They usually range from 1mm to 5mm, depending on current needs.

    2. Can copper inlays be used in multi-layer PCBs?

    Yes, with proper planning, copper inlays can be included in multi-layer designs.

    3. How are copper inlays secured to the board?

    Inlays are typically bonded using lamination, plating, or soldering.

    4. What current can a copper inlay PCB handle?

    With proper design, it can handle 100A or more safely.

    5. Are copper inlay PCBs better than thick copper PCBs?

    For localized high current and heat, yes. Copper inlays offer better efficiency and design flexibility.

    If you’re looking to upgrade your PCB design with copper inlays for better performance and reliability, contact Best Technology today. Our team is ready to help with design consultation, sample production, and mass manufacturing. Get a custom copper inlay PCB quote today!

    Metal Core PCB Material: Types, Properties & Applications
    Friday, July 25th, 2025

    When it comes to managing heat in high-power electronic devices, Metal Core PCBs (MCPCBs) are the go-to solution. These boards use a metal base—typically aluminum or copper—to efficiently dissipate heat for LEDs, power modules, and automotive systems. However, the effectiveness of an MCPCB depends heavily on the material chosen for its core and dielectric layers.

    At Best Technology, we specialize in custom MCPCB fabrication using materials from leading global brands like Laird, Bergquist, and Ventec. Whether you need aluminum-based MCPCBs for LED lighting or copper-core boards for power electronics, we offer full support from material selection to prototyping and mass production. In this blog, we will share some information about metal core PCB materials, help you to understand MCPCB from the inside to out.

    Metal Core PCB Material: Types, Properties & Applications

    What Is Metal Core PCB?

    A metal core PCB (MCPCB) is a printed circuit board that uses a metal base instead of traditional fiberglass (FR4). This metal base acts as a heat spreader, drawing heat away from components that generate significant thermal energy during operation.

    In a typical MCPCB, the structure includes three key layers:

    • Copper Circuit Layer – for electrical connections.
    • Dielectric Layer – an insulating layer that separates the copper from the metal core, allowing heat transfer but preventing electrical conduction.
    • Metal Core (Base Layer) – typically aluminum, copper, or stainless steel, used to conduct heat away from the board.
    Metal Core PCB structure

    These PCBs are engineered to handle thermal management more efficiently than standard PCBs. As electronic devices become more compact and powerful, effective heat dissipation becomes more important, and MCPCBs offer a practical solution.

    Common Metal Core PCB Materials

    There are several options when it comes to metal core PCB material, each with its own unique benefits. The choice depends on factors like thermal requirements, mechanical strength, weight, and budget.

    1. Aluminum Core

    Aluminum is the most commonly used metal core material in MCPCBs. It is lightweight, cost-effective, and has good thermal conductivity—typically around 205 W/m·K. Aluminum cores are ideal for LED lighting, consumer electronics, and automotive circuits where heat must be dissipated efficiently, but extreme thermal loads are not present. The commonly used aluminum core PCB in Best Technology is 5052, 6061, 3003, here is the datasheet of them:

    Property6061 Aluminum5052 Aluminum3003 Aluminum
    Material TypeAl-Mg-SiAl-MgAl-Mn
    Tensile Strength (MPa)290 – 350190 – 260130 – 200
    Yield Strength (MPa)240160 – 200115 – 150
    Elongation at Break (%)10 – 1712 – 2015 – 20
    Thermal Conductivity (W/m¡K)167138159
    Density (g/cmÂł)2.702.682.73
    Melting Point (°C)582 – 652607 – 650643 – 657

    2. Copper Core

    Copper is used where superior heat dissipation is needed. It has excellent thermal conductivity—around 385 W/m·K—and is suitable for high-power applications such as power supplies, industrial equipment, and RF systems. While it offers the best performance in terms of heat transfer, it is also heavier and more expensive than aluminum.

    3. Stainless Steel Core

    Stainless steel is rarely used, but it can be found in certain niche applications where corrosion resistance and mechanical strength are more important than thermal performance. Its thermal conductivity is much lower, around 16 W/m¡K, making it suitable only for specific use cases.

    Metal Core PCB Material Manufacturers

    When choosing a metal core PCB manufacturer, it’s important to work with companies that supply high-quality materials and have a track record of consistency and reliability. Below are some of the leading manufacturers of metal core PCB materials that we cooperating:

    • Bergquist (Henkel)
    • Ventec
    • Polytronics (Taiwan)
    • Boyu (China)
    • Laird Technologies
    • Totking (China)
    • Dupont Clamcool
    • XianYang Bode electronic

    Why Thermal Conductivity Is Important in MCPCB?

    The thermal conductivity of a material refers to the amount of heat it can transfer under stable conditions. Specifically, for a 1-meter-thick material, if the temperature difference between two surfaces is 1°C, and heat transfer occurs through 1 square meter within 1 hour, the quantity of heat transferred is expressed in W/m¡K (watts per meter-kelvin). For practical use, K (kelvin) can often be replaced by °C.

    The thermal conductivity value depends on the material’s composition, density, moisture content, and temperature. Materials with lower density or non-crystalline structures tend to have lower thermal conductivity, while materials with higher density and metallic bonding structures transfer heat more efficiently.

    Generally, materials with low thermal conductivity are referred to as thermal insulators, and those with a conductivity below 0.05 W/m¡K are called high-efficiency insulation materials. In contrast, metals typically exhibit high thermal conductivity, which makes them ideal for use in metal core PCBs.

    Thermal Conductivity of Common Metals Materials

    MetalThermal Conductivity (W/m¡K)
    Silver429
    Copper401
    Gold317
    Aluminum237
    Iron80
    Lead67
    Zinc34.8

    As seen in the table above, silver has the highest thermal conductivity, followed by copper and gold. However, due to cost and practicality, copper and aluminum are the most commonly used metals in MCPCBs. Aluminum strikes a balance between cost, weight, and thermal performance, while copper is chosen for extreme thermal demands.

    1W vs 2W vs 3W Thermal Conductivity Differences

    When evaluating MCPCB materials, it’s essential to consider not only the core metal but also the thermal conductivity of the dielectric layer. This layer sits between the copper circuitry and the metal base. In the metal core pcb manufacturing, the commonly used dielectric layers are 1W, 2W and 3W.

    • 1W/m¡K: Basic dielectric material, suitable for low-power circuits and LEDs with minimal heat output.
    • 2W/m¡K: Offers moderate thermal performance, ideal for mid-power LEDs and general electronics.
    • 3W/m¡K or higher: Designed for high-power LEDs or circuits that generate significant heat, ensuring efficient transfer to the metal core.

    Choosing a higher thermal conductivity dielectric can greatly reduce thermal resistance, leading to better overall cooling performance. But not the higher the better, it should depends on your specific demands.

    Aluminum PCB vs Copper Core PCB

    When comparing aluminum PCBs and copper core PCBs, the main differences come down to thermal performance, cost, and application needs. Both are types of metal core PCBs (MCPCBs), but they serve different purposes depending on how much heat your circuit generates and how much budget you have.

    Aluminum PCB is the most commonly used metal core because it offers a good balance of performance, weight, and affordability. It provides moderate thermal conductivity (around 237 W/m¡K) and is suitable for many applications, especially LED lighting, consumer electronics, and automotive circuits where heat is present but manageable. Aluminum is also lightweight, making it easier to handle and mount, especially in devices where weight matters.

    Copper core PCB, on the other hand, offers superior thermal conductivity (around 401 W/m¡K if used directly thermal path technology), nearly double that of aluminum. This allows it to handle more heat, which is crucial in high-power electronics, RF systems, and industrial power converters. However, copper is heavier and more expensive, so it’s typically used only when the highest level of heat dissipation is required.

    Can I Use Aluminum PCB in High Power LED Lighting?

    Yes, aluminum PCBs are widely used in high-power LED lighting, especially when paired with high thermal conductivity dielectric materials. These boards effectively dissipate heat away from LEDs, preventing overheating and maintaining light output stability.

    However, the design must ensure:

    • Adequate heat spreading area
    • Proper thickness of aluminum core (typically 1.0mm to 1.6mm)
    • High-quality dielectric layer with 2W or 3W thermal conductivity

    In cases where LEDs generate extreme heat, consider using copper MCPCBs or combining the aluminum core with external heat sinks for better performance.

    How to Choose the Right MCPCB Material for LED Projects?

    Selecting the correct metal core PCB material for your LED project involves analyzing the following:

    • Thermal Output of LEDs

    Higher wattage LEDs generate more heat. For low-power LEDs, aluminum with 1W/m·K dielectric is sufficient. For high-power LEDs, choose aluminum or copper with 2W–3W dielectric.

    • Mechanical Requirements

    If the PCB must endure vibration or mechanical stress (e.g., automotive lighting), choose thicker copper for added durability.

    • Budget Considerations

    Aluminum offers a cost-effective balance between performance and price. Copper is more expensive and should be reserved for projects where thermal performance cannot be compromised.

    • Weight Constraints

    In portable or ceiling-mounted LED systems, lightweight aluminum helps reduce the overall weight of the fixture.

    Metal Core PCB Applications

    • LED Lighting: Used in street lights, automotive lights, grow lights, and flood lights to ensure LEDs stay cool.
    • Power Electronics: Found in motor controllers, inverters, and converters to handle large currents and heat.
    • Automotive: Used in ECUs, headlights, and battery systems for reliable performance in harsh environments.
    • Telecommunications: Applied in RF modules, power amplifiers, and antenna systems.
    • Consumer Devices: Used in high-performance audio systems and power adapters.

    Best Technology – Your Online Partner in MCPCB Manufacturing

    At Best Technology, we specialize in the design and production of metal core PCBs for various industries. Whether you need aluminum or copper-based boards, we deliver customized thermal solutions to meet your specific project needs. By choosing Best Technology, you can enjoy:

    • 99% on-time delivery
    • Highest quality that conforms to IATF16949
    • Factory prices with no MOQ
    • High mixed varieties: aluminum pcb, copper PCB, directly thermal path PCB, ims pcb
    • Multiply surface finish: OSP, HASL, ENIG, ENEPIG
    • Turnkey PCB & PCBA assembly
    • Flexible Production: From prototypes to high-volume manufacturing
    • Free DFM & DFA checks
    • 24/7 online sales

    FAQs

    Q1: What thickness is standard for aluminum MCPCBs?

    Typical thicknesses range from 1.0mm to 1.6mm, depending on mechanical strength and thermal needs.

    Q2: Is copper MCPCB worth the extra cost?

    Yes, in high-power applications where superior thermal performance is necessary, copper is a valuable investment.

    Q3: Can I request a custom thermal analysis?

    Absolutely. Best Technology provides thermal analysis and simulation support to ensure the right material choice.

    Q4: Are there standard sizes for MCPCB panels?

    Yes, but we also offer custom sizes based on your design files and project needs.

    Q5: How can I get a quote for metal core PCBs?

    Send your Gerber files, project details, and thermal requirements to Best Technology. Our team will respond within 12 hours.

    Electronic Component Failure Analysis: Why it occurs?
    Friday, July 18th, 2025

    What Is Electronic Component Failure?

    When any part inside an electronic system stops working as expected, it’s called an electronic component failure. This could mean a capacitor no longer holds charge, a resistor burns out, or an integrated circuit malfunctions. Even one small faulty component can lead to major issues in the final product.

    To find out why a component failed, engineers use a process called electronic component failure analysis. This process involves inspecting the part visually and electrically, identifying how and why the fault happened, and using that information to avoid similar problems in the future. It’s essential for quality assurance, product reliability, and cost control in any electronics-related business.

    Electronic Component Failure Analysis

    Types of Electronic Component Failure

    Electronic components can fail in different ways depending on the stress they endure. Below are the four most common types:

    1. Mechanical Failure

    Mechanical failure happens when there is a physical breakdown of the component’s structure. Some failures are often caused by vibration, improper handling, or dropping a device. In mobile or automotive electronics, this type of failure is especially common due to frequent movement. Common typical failures are including:

    • Cracked solder joints
    • Broken leads or pins
    • Fractured PCB substrates
    • Loose connectors due to vibration

    You might notice components that are no longer connected properly to the board or parts that move when touched. Visual inspection often reveals cracks or loosened parts caused by physical force.

    2. Thermal Failure

    All electronic parts generate some heat when they operate. However, if the heat is not controlled properly, components can overheat and become damaged. This is known as thermal failure.

    For example, semiconductors like transistors and integrated circuits are sensitive to high temperatures. When they get too hot, their internal structure may break down, leading to permanent damage.

    3. Aging Failure

    Components have a natural lifespan. Over time, materials degrade, and the component can no longer perform its function correctly. This is called aging failure.

    Electrolytic capacitors are well-known for this issue—they tend to dry out after years of use, causing them to lose their ability to hold charge. Similarly, solder joints can crack after repeated heating and cooling cycles (called thermal cycling), leading to poor connections.  In addition to this, typical aging failures also including:

    • Metal fatigue in solder joints
    • Battery capacity reduction
    • Deteriorated dielectric layers

    4. Packaging Failure

    Electronic components are enclosed in packaging to protect the inner materials. If the packaging is flawed or gets damaged during use, it may expose the component to moisture, dust, or chemicals.

    For instance, water vapor may seep through a cracked chip case and cause corrosion inside. This is especially risky in humid or corrosive environments. Packaging failure is often seen as cracking, blistering, or delamination of the part’s outer shell.

    Types of Electronic Component Failure

    Causes of Electronic Component Failure

    To solve problems effectively, it’s important to understand the root causes behind failures. Below are the most common causes engineers encounter during electronic component failure analysis:

    1. Overvoltage and Overcurrent

    Every electronic component has a maximum voltage and current rating. Exceeding these limits can damage the internal structure, often leading to immediate failure. For example, sending too much current through a resistor can cause it to overheat and burn. Applying excessive voltage to a capacitor can cause it to explode or leak.

    2. Poor Soldering or Manufacturing Defects

    Faulty assembly techniques can lead to short circuits, intermittent connections, or component movement. Cold solder joints—where the solder didn’t melt completely—can crack over time.

    If a component is misaligned or not soldered properly to all its pads, it may not function or may fail under mechanical stress. These defects are usually caught through visual inspection or X-ray analysis.

    3. Electrostatic Discharge (ESD)

    Static electricity may not hurt humans, but it can destroy sensitive components like MOSFETs and ICs instantly. Even a small ESD event can damage internal junctions, creating invisible faults that show up later during use.

    4. Environmental Stress

    Moisture, dust, salt, or chemicals in the air can corrode metal parts, especially in outdoor or industrial environments. Extreme temperatures or frequent thermal cycling can stress materials, causing them to crack or delaminate.

    5. Inadequate Design or Component Selection

    Using the wrong part for the job—such as a low-voltage capacitor in a high-voltage section—can lead to early failure. Similarly, ignoring derating rules (operating parts near their limit) can reduce lifespan dramatically.

    How to Check Faulty Electronic Components?

    When a device isn’t working, checking the components one by one is a logical step. Here’s how to do that effectively:

    1. Visual Inspection

    The first step is always to look carefully. Use a magnifying glass or microscope if needed. There are some signs can be checked directly if components get failure. Look for:

    • Burn marks or discoloration
    • Cracks or broken legs
    • Bulging or leaking capacitors
    • Lifted or cracked solder joints
    • Warping or melting

    2. Smell

    Burnt electronic parts release a strong smell. If a section of the board smells like burnt plastic or metal, you’re probably close to the damaged part.

    3. Touch Test (with Caution)

    Once the power is OFF and the board is safe to handle, you can gently feel components. If one feels much hotter than the rest, it may be failing. Never touch live circuits, and use caution even when power is removed—capacitors may still hold a charge.

    4. Comparison Method

    If you have an identical working device, compare it with the faulty one. Swapping parts one by one can help isolate which component isn’t working.

    5. Multimeter Testing

    A digital multimeter is your best tool. You can test for open circuits, shorts, or measure resistance, voltage, and continuity. We’ll explain this in the next section in detail.

    How to Prevent Electronic Component Failures?

    While you can’t prevent all failures, many of them can be avoided with good design, handling, and maintenance practices.

    • Always source your components from reputable suppliers. Cheap or counterfeit parts are far more likely to fail.
    • Avoid pushing components near their max voltage, current, or temperature limits.
    • Add surge protection (like TVS diodes or fuses) where needed.
    • Use appropriate PCB layout techniques for signal integrity and thermal control.
    • Use anti-static wrist straps and mats when handling sensitive parts.
    • Store components in anti-static bags or boxes.
    • Avoid touching component pins directly.
    • Good soldering practices and correct part orientation go a long way. Automated optical inspection (AOI) and in-circuit testing (ICT) help ensure quality during production.
    • For circuits exposed to moisture or dust, apply conformal coating or potting material to prevent corrosion and shorts. Use enclosures with proper IP ratings if the device will be outdoors.
    • Use heatsinks, thermal vias, fans, or thermal pads to keep parts cool. High temperatures shorten component life more than almost any other factor.

    How to Test Electronic Components with a Multimeter?

    A multimeter is one of the most useful tools for checking components, it can be tested various parts, here is how to test:

    How to Test Electronic Components with a Multimeter?

    1. Testing Capacitors

    • Discharge the capacitor before testing.
    • Set the multimeter to capacitance mode (if available).
    • Connect probes to the leads.

    A large difference between the reading and rated value suggests aging or failure.

    Note: If your multimeter lacks capacitance mode, you can test for short or open conditions using resistance mode.

    2. Testing Diodes and LEDs

    • Set the meter to diode test mode.
    • Connect the red probe to the anode and the black to the cathode.
    • A good diode should show a forward voltage drop (~0.6–0.7V).
    • Reversing the probes should show no reading.

    LEDs can also be tested this way, and a faint light may even flash when tested in forward bias.

    3. Testing Transistors

    Bipolar junction transistors (BJTs) can be tested by checking base-emitter and base-collector junctions like diodes.

    • Use diode mode.
    • Test base-to-emitter and base-to-collector—each should show ~0.6V in forward bias.
    • Reversed probes or collector-to-emitter should show no conduction.
    • If you get readings in all directions, the transistor may be shorted.

    4. Testing ICs

    Integrated circuits are difficult to test with just a multimeter. You usually need to power the board and check input/output signals or use dedicated IC testers.

    FAQs

    1. What is the first sign of electronic component failure?

    Burn marks, strange smells, or malfunctioning behavior are common early signs of component issues.

    2. How do you test an electronic component without removing it from the circuit?

    You can test many components in-circuit using a multimeter, but readings may be affected by parallel components.

    3. How often should electronics be inspected for aging components?

    Critical systems should be checked annually, while consumer devices may only need service after several years.

    4. What is the role of derating in preventing failures?

    Derating means operating components below their maximum limits to reduce stress and increase reliability.

    5. Can failure analysis improve future product design?

    Yes, analyzing failed parts helps engineers refine design, choose better materials, and improve overall durability.

    If you’re working on a repair or want to improve your product’s reliability, proper electronic component failure analysis is a valuable step. Want help with failure diagnostics or reliable PCB assembly? Reach out to Best Technology — your trusted partner for high-quality, certified PCB and PCBA solutions.

    We follow strict quality control with quality control systems, and offer full traceability for manufacturing, report, datasheet… If you want to do PCB assembly or components sourcing, welcome to reach us at sales@bestpcbs.com.

    What is EMS in Electronics?
    Wednesday, July 16th, 2025

    EMS refers to a range of services offered by specialized companies that design, assemble, test, and distribute electronic components or assemblies. These services are crucial to the electronics supply chain, especially as companies seek faster production, cost-effective solutions, and greater focus on innovation rather than internal manufacturing processes. In this article, we will explain the EMS meaning in electronics, how it differs from OEM, and why it’s becoming the preferred solution for many industries.

    What Does EMS Stand for in Electronics?

    In electronics, EMS stands for Electronic Manufacturing Services. It describes companies that offer a full range of manufacturing services for electronic products on behalf of original equipment manufacturers (OEMs). EMS companies handle everything from printed circuit board assembly (PCBA) to box builds, testing, and even logistics.

    The EMS meaning in electronics has evolved over the years. Initially focused only on assembly, EMS now covers the entire product lifecycle, including design assistance, prototyping, materials sourcing, final product integration, and post-sales services. EMS helps companies reduce production costs, improve lead times, and maintain high-quality standards without building their own manufacturing facilities.

    What Does EMS Stand for in Electronics?

    What Is the Difference Between OEM and EMS?

    Many people confuse OEM (Original Equipment Manufacturer) with EMS, but they serve very different purposes.

    • An OEM is responsible for the product concept and design. OEMs usually create the brand, own the intellectual property (IP), and manage marketing and distribution. However, they often outsource the actual manufacturing to EMS providers.
    • An EMS company specializes in manufacturing electronics based on the OEM’s design. They may offer additional services such as design optimization and testing, but they don’t usually own the product IP.

    For example:

    A tech startup designs a wearable fitness tracker. They are the OEM. Instead of setting up a factory, they work with an EMS provider to manufacture the product, conduct functional testing, assemble the final unit, and ship it globally.

    What Do EMS Providers Do?

    EMS providers offer a full suite of services that span from initial design consultation to final product shipment. These services typically include:

    • PCB assembly (SMT & THT)
    • Sourcing of electronic components
    • Design for manufacturing
    • Engineering Support
    • Prototype service
    • Testing and inspection (ICT, FCT, AOI, X-RAY, etc.)
    • Mechanical assembly
    • Box build and system integration
    • Packaging and logistics (depends on the payment terms)

    EMS companies play a central role in bridging the gap between product design and final delivery. Businesses that don’t own manufacturing plants—or wish to scale quickly—can rely on EMS companies to handle production, logistics, and even after-sales support.

    What Do EMS Providers Do?

    Common Industries That Rely on EMS Solutions

    Many industries especially for electronic industry depend on EMS companies due to the complex nature of electronic product development and production. Some common industries include:

    1. Consumer Electronics

    Smartphones, tablets, wearables, and gaming consoles are often produced in partnership with EMS companies, who manage high-speed assembly and short product lifecycles.

    2. Medical Devices

    From diagnostic equipment to portable health monitors, EMS companies provide precision assembly and documentation that comply with strict medical regulations (e.g., ISO13485).

    3. Automotive Electronics

    Modern vehicles are full of electronic control units (ECUs), infotainment systems, sensors, and cameras. EMS partners help automakers achieve reliability and consistency.

    4. Telecommunications

    Routers, base stations, and networking equipment require robust PCBA and quick scalability—ideal for EMS manufacturing models.

    5. Industrial Automation

    Controllers, PLCs, and robotics equipment are often built by EMS providers, ensuring durability and performance in tough environments.

    Benefits of Working with EMS Companies

    Working with EMS companies brings many advantages, especially for businesses looking to optimize operations and reduce overhead.

    1. Cost Reduction

    EMS providers work at scale, reducing material costs, labor expenses, and production waste. Their optimized processes bring significant cost savings compared to in-house manufacturing.

    2. Faster Time to Market

    EMS companies are built for speed. They streamline procurement, assembly, and testing, helping OEMs launch products more quickly.

    3. Production Flexible

    Whether you’re building 100 units or 100,000, EMS providers can ramp up production based on your needs.

    4. Access to Skilled Labor and Advanced Equipment

    With a dedicated team of engineers, technicians, and quality experts, EMS partners ensure high-quality output using modern equipment.

    5. Reduced Supply Chain Complexity

    EMS providers handle sourcing, logistics, and inventory management, reducing the burden on the OEM and improving reliability.

    6. Global Reach

    Some EMS companies offer local manufacturing as well as global distribution, making it easier to reach customers worldwide.

    Electronic Manufacturing Services (EMS) Companies in China

    China is home to some of the world’s most established electronic manufacturing services providers. These companies support global clients by offering:

    • Competitive pricing
    • Fast turnaround
    • Mature supply chains
    • Skilled engineering teams
    • High-volume production capabilities

    Whether it’s smartphones, industrial controllers, or IoT devices, many companies prefer to work with electronic manufacturing services (EMS) companies in China for their ability to handle rapid prototyping, complex assembly, and scalable production.

    Chinese EMS companies often provide end-to-end solutions—from prototyping to full product assembly—and are favored by startups and global brands alike. Some common PCB EMS provider like:

    • PCBWay
    • JLCPCB
    • Best Technology
    • ALLPCB
    • Hitech Circuits Co., Ltd.
    • NextPCB
    • Rayming PCB
    Electronic Manufacturing Services (EMS) Companies in China

    Why Best Technology Is a Trusted EMS Partner?

    Best Technology is a professional EMS provider based in China, offering complete manufacturing services to clients worldwide. We are committed to delivering reliable, high-quality electronics tailored to customer requirements.

    • We are certified to ISO9001, ISO13485, IATF16949, AS9100D, UL, RoHS, ensuring that every product meets global quality standards.
    • From PCB fabrication to final assembly and logistics, we provide turnkey EMS solutions that shorten lead times and reduce complexity.
    • Our experienced team helps optimize your designs for better performance and lower production costs.
    • With strong supply chain relationships and efficient production methods, we offer fair pricing without compromising quality.
    • We serve clients in North America, Europe, and Asia, with strong communication and technical support.

    Whether you need rapid prototypes or high-volume manufacturing, Best Technology is ready to be your trusted EMS partner.

    FAQs

    1. What is EMS meaning in electronics?

    EMS stands for Electronic Manufacturing Services. It refers to companies that manufacture, assemble, and test electronic components or systems for other businesses.

    2. How is EMS different from OEM?

    OEMs design and brand products, while EMS companies focus on manufacturing and assembly based on OEM specifications.

    3. Why do businesses prefer EMS providers?

    EMS partners help reduce cost, speed up product launches, and allow companies to focus on design and sales instead of manufacturing.

    4. Are EMS companies only for large corporations?

    No. Many small and medium-sized businesses rely on EMS companies for prototyping, small-batch runs, and full production.

    5. What makes Best Technology a reliable EMS company?

    Best Technology offers certified quality, full traceability, engineering support, and turnkey EMS solutions backed by years of experience in the industry.

    Rogers PCBs – The Ideal Choice for High-Speed Communication
    Saturday, July 12th, 2025

    In Best Technology, the printed circuit Board manufacturing, particularly in high-frequency and high-speed signal transmission applications, Rogers Corporation’s PCB materials have become the go-to choice for our engineers. Rogers specializes in producing high-performance, highly reliable circuit board materials that find extensive use in wireless communications, automotive radar, satellite communication, and more. This blog post explores the unique advantages of Rogers PCBs and their significance in the international market.

    Rogers PCBs – The Ideal Choice for High-Speed Communication

    What is Rogers PCB?

    Rogers PCBs are renowned for their exceptional electrical performance. Compared to traditional FR-4 materials, Rogers materials offer a lower dissipation factor (Df), meaning they can maintain signal integrity at higher frequencies with reduced energy loss. This is critical for applications requiring precise data transmission such as 5G communications and millimeter-wave radars.

    Rogers materials exhibit outstanding thermal stability. In high-temperature environments, these materials retain dimensional stability and mechanical strength, ensuring the reliability of PCBs under extreme conditions. For devices that need to operate stably over long periods, such as base stations or satellite communication equipment, this feature is especially important. Here is a comparison between Rogers materials and FR4.

    PropertyRogers MaterialFR4 Material
    Dielectric Constant (Dk)Low and stable (e.g. 2.2 – 3.5)Higher and less stable (around 4.3 – 4.8)
    Loss Tangent (Df)Very low (as low as 0.0009)Higher (typically ~0.02)
    Signal LossMinimal, ideal for high-frequency applicationsMore signal loss at high frequencies
    Frequency PerformanceExcellent at RF/microwave frequencies (GHz range)Poor performance above 1 GHz
    Thermal StabilityExcellent (low Dk variation with temperature)Moderate
    Thermal ConductivityHigher (improves heat dissipation)Lower
    CostHighLow
    Material CompositionCeramic-filled or hydrocarbon-based laminatesWoven glass epoxy resin
    ApplicationRF, microwave, satellite, aerospace, radar, 5GConsumer electronics, computers, industrial devices
    Moisture AbsorptionVery lowHigher
    Impedance ControlBetter and more predictableLess accurate
    ManufacturabilityRequires experienced processing (different drilling etc.)Easy to process using standard PCB methods

    Moreover, Rogers offers a range of materials with different characteristics to cater to various application needs. From low-loss to ultra-high-frequency applications, customers can choose the most suitable material based on their specific requirements. This not only enhances design flexibility but also provides more solutions to address complex engineering challenges.

    In the context of globalization, competition in the international market has intensified. Utilizing Rogers PCB materials not only elevates the technical content and competitiveness of products but also offers customers a superior service experience. With the widespread adoption of 5G technology and the development of the Internet of Things (IoT), the demand for high-performance PCBs will continue to grow, making Rogers a leader in this field.

    Advantages of Rogers PCB

    1. Superior High-Frequency Performance

    Rogers PCBs offer excellent electrical performance at high frequencies. Their stable dielectric constant and low loss tangent minimize signal loss and dispersion, which is critical for RF and microwave applications.

    2. Low Dielectric Loss

    Rogers materials have very low Df (dissipation factor), reducing power loss during signal transmission. This makes them highly efficient for high-speed, high-frequency signal paths.

    3. Excellent Thermal Management

    Rogers laminates have better thermal conductivity compared to standard FR4, allowing for more efficient heat dissipation. This helps maintain performance in demanding temperature environments.

    4. Stable Electrical Properties

    Their dielectric constant remains consistent over a wide range of temperatures and frequencies, enabling precise impedance control and signal integrity in advanced circuit designs.

    5. Low Moisture Absorption

    Rogers materials absorb less moisture than FR4, making them reliable for outdoor, aerospace, or high-humidity environments.

    6. Better Reliability for Harsh Environments

    With high temperature resistance and chemical stability, Rogers PCBs perform well in aerospace, military, and industrial applications where standard FR4 may fail.

    Rogers PCBs – The Ideal Choice for High-Speed Communication

    Applications of Rogers PCB

    1. RF and Microwave Circuits

    Rogers PCBs are widely used in radio frequency (RF) and microwave communication systems, including antenna arrays, radar modules, and RF amplifiers.

    2. 5G Infrastructure

    Due to their low signal loss and excellent high-frequency characteristics, Rogers boards are ideal for 5G base stations, antennas, and network hardware.

    3. Aerospace and Defense Systems

    In aviation, satellites, and military electronics, Rogers PCBs provide the precision and durability needed for mission-critical communication and control systems.

    4. Automotive Radar and ADAS

    Modern vehicles use Rogers-based PCBs in advanced driver assistance systems (ADAS), radar sensors, and collision avoidance modules for reliable performance under extreme conditions.

    5. Medical Imaging and Equipment

    Rogers boards are used in MRI machines, RF ablation devices, and other diagnostic tools where consistent signal performance is crucial.

    6. High-Speed Digital Circuits

    In computing and telecommunications, Rogers materials support high-speed signal integrity for backplanes, routers, and high-frequency data transmission boards.

    Applications of Rogers PCB

    Conclusion

    Rogers PCBs stand out globally due to their outstanding performance and broad applicability. Whether developing new communication devices or improving existing systems, choosing Rogers is a wise decision. Their commitment to innovation ensures they remain at the forefront of technological advancement, providing unparalleled solutions for tomorrow’s electronic challenges.

    Best Tech is a very professional manufacturer in printed circuit board. If you are interesting to know more information for Rogers PCB and other high-speed signal transmission application for printed circuit board, please come to contact us at any time.

    8-Layer PCB Stackup Design Guide | Best Technology
    Friday, July 11th, 2025

    Designing a reliable multilayer circuit board starts with getting the stackup right. If your project involves high-speed signals, compact layouts, or reduced EMI, an 8-layer PCB stackup is a solid choice. It offers flexibility, better performance, and room for complex routing.

    In this guide, we’ll walk you through everything you need to know—layer configurations, materials, sizes, and how to make the most of this structure with the help of a trusted PCB manufacturer.

    8-Layer PCB Stackup Design Guide

    What is a PCB Stackup?

    A PCB stackup is the arrangement of copper layers and insulating materials inside a circuit board. These layers are stacked and bonded together using prepreg (resin-impregnated fiberglass) and core materials. The goal is to create a reliable board that supports both mechanical strength and excellent electrical performance.

    In simple words, the stackup decides how signal layers, power planes, and ground layers are placed in the board. In high-speed digital designs, this structure plays a big role in signal quality, electromagnetic compatibility (EMC), and overall performance.

    For an 8-layer PCB, the stackup consists of eight layers of copper with alternating dielectric materials. These are usually divided into four signal layers and four plane layers, though that can change based on your design needs.

    PCB Stackup Considerations

    For most PCB designs, there are often competing requirements between electrical performance, manufacturing limitations, cost targets, and system complexity. The final PCB stackup is usually a result of careful trade-offs across these factors. High-speed digital circuits and RF systems commonly rely on multilayer boards for better control and performance. Below are 8 essential principles to consider when designing a reliable stackup:

    1. Layer Arrangement

    In multilayer PCBs, you’ll typically work with signal layers (S), power planes (P), and ground planes (GND). Power and ground planes are usually solid, unbroken areas that provide low-impedance return paths for signal currents. Signal layers are often positioned between these planes to form symmetrical or asymmetrical stripline structures. The top and bottom layers are mainly used for component placement and limited routing. It’s best to keep traces on these outer layers short to reduce direct radiation and EMI.

    PCB Stackup Considerations

    2. Defining a Single Power Reference Plane

    Decoupling capacitors are vital for maintaining power integrity, and they can only be placed on the outer layers of the PCB. The trace length, pad design, and vias connected to these capacitors greatly affect their effectiveness. To improve decoupling, make these connections short and wide, and minimize via length. For example, in a high-speed digital system, place decoupling capacitors on the top layer, dedicate the second layer to power for the processor, use the third layer for signal routing, and assign the fourth layer as a ground reference.

    3. Incorporating Multiple Ground Planes

    Using multiple ground planes helps create low-impedance return paths and minimizes common-mode EMI. Ground and power planes should be tightly coupled, and signal layers should also be close to reference planes. Reducing the dielectric thickness between layers improves coupling and enhances performance.

    4. Managing Multiple Power Planes

    When your design includes more than one power plane, these planes are often split into different voltage regions. If a signal layer is placed next to a multi-region power layer, signal currents may not find clean return paths, leading to noise or EMC issues. For high-speed digital signals, avoid routing traces near split power planes to prevent return current discontinuities.

    5. Designing Signal Routing Pairs

    When a signal travels from one layer to another, it creates what’s known as a “routing pair.” Ideally, the return current should stay within the same reference plane when switching layers. In practice, however, signals often need to transition between layers. To maintain signal integrity, ensure that return paths are available through stitching vias or decoupling capacitors. Using adjacent layers as routing pairs is a practical and effective strategy.

    6. Routing Direction Guidelines

    Keep trace directions consistent within each signal layer. At the same time, rotate the routing direction between adjacent signal layers. For instance, use horizontal routing (X-axis) on one layer and vertical routing (Y-axis) on the next. This practice reduces crosstalk and improves signal clarity.

    7. Even-Layer Designs is Better

    Although odd-layer PCBs may appear cheaper due to fewer materials, they’re more expensive to manufacture. That’s because odd-layer boards require non-standard lamination processes and additional handling steps. These increase the risk of surface damage, incorrect etching, and longer production times. In contrast, even-layer PCBs are more stable, cost-effective, and easier to produce at scale.

    PCB Stackup Considerations

    8. Budget

    Multilayer PCBs are naturally more expensive than single- or double-layer boards. However, they offer significant benefits in functionality, miniaturization, EMI control, and signal integrity. When weighing total cost versus performance, the difference between multilayer and simpler boards may not be as high as expected.

    Standard 8-Layer PCB Stackup Structure

    When it comes to multilayer PCB design, the arrangement of signal, power, and ground layers directly affects signal integrity, EMI performance, and power delivery. Below are three common 8-layer stackup configurations, each with its own strengths and limitations.

    Standard 8-Layer PCB Stackup Structure

    Option 1:

    Layer 1: Signal 1

    Layer 2: Signal 2

    Layer 3: Ground

    Layer 4: Signal 3

    Layer 5: Signal 4

    Layer 6: Power

    Layer 7: Signal 5

    Layer 8: Signal 6

    This layout alternates signal and power layers but does not take full advantage of the electromagnetic shielding benefits that a multilayer board can offer. The ground and power planes are separated, reducing the board’s EMI suppression capability. In addition, the power distribution network suffers from higher impedance, which may affect voltage stability in high-speed or high-current applications.

    Option 2:

    Layer 1: Signal 1

    Layer 2: Ground

    Layer 3: Signal 2

    Layer 4: Power

    Layer 5: Ground

    Layer 6: Signal 3

    Layer 7: Ground

    Layer 8: Signal 4

    This structure is widely regarded as the optimal 8-layer PCB stackup. It provides excellent electromagnetic shielding through the use of multiple ground planes. Each signal layer is placed adjacent to a reference plane (either ground or power), which improves signal stability and impedance control. Additionally, the tight coupling between power and ground planes enhances EMI performance and power integrity. This setup is ideal for high-speed, high-frequency, or noise-sensitive applications.

    Option 3:

    Layer 1: Signal 1

    Layer 2: Ground

    Layer 3: Signal 2

    Layer 4: Power

    Layer 5: Ground

    Layer 6: Signal 3

    Layer 7: Power

    Layer 8: Signal 4

    This configuration is a variation of Option 1 with improved EMI performance. By adding an extra reference plane, it provides better control over the characteristic impedance of the signal layers. However, the placement of the second power plane (with limited coupling to a nearby ground) leads to higher power delivery impedance, which could be a drawback in power-sensitive designs. Some optimization in power layer arrangement is still needed.

    8-Layer PCB Stackup Materials

    The performance of an 8-layer PCB stackup relies heavily on the materials used between and around its copper layers. These materials affect everything from electrical behavior to thermal stability and even mechanical strength. Let’s look at the two main categories: conductive and dielectric materials.

    1. Conductive Layers

    Copper is the most common metal used for the conductive layers in an 8-layer PCB. It’s highly conductive, easy to work with, and available in different thicknesses and finishes.

    • Copper Thickness: Most boards use ½ oz or 1 oz copper per layer. If the design needs to handle higher current, 2 oz or thicker copper may be used.
    • Copper Type: Standard copper foil is either electrodeposited (ED) or rolled. Rolled and annealed copper is smoother and more flexible, which makes it useful in boards that need better bend resistance.
    • Surface Finishes: The exposed copper is usually treated with a surface finish to protect it and ensure solderability. Options include HASL, ENIG, OSP, and immersion silver, among others.

    2. Dielectric Layers

    The dielectric materials are the insulating layers that separate the copper traces. These layers are critical for controlling impedance, heat flow, and electrical isolation.

    • FR-4: A glass-reinforced epoxy laminate, FR-4 is the most common dielectric for general-purpose PCBs. It’s reliable, widely available, and cost-effective.
    • High-Frequency Materials: For RF and high-speed digital designs, materials with low dielectric loss—like PTFE (Teflon), ceramic-filled PTFE, or hydrocarbon-based ceramics—are preferred. These support better signal integrity at high frequencies.
    • Thermal Conductive Materials: When heat dissipation is a concern, substrates like alumina or aluminum nitride are used. These materials offer higher thermal conductivity than standard epoxy systems.

    To hold everything together, manufacturers use prepregs—uncured fiberglass sheets soaked in resin. Common prepreg materials include FR-4 for standard designs and polyimide for higher thermal or mechanical stress environments.

    At the center of the stackup is the core, which acts like a spine for the board. This rigid layer typically uses FR-4 or polyimide, though in some high-power or high-heat applications, metal cores are added to improve thermal performance.

    8-Layer PCB Thickness & Sizes

    The total thickness of an 8-layer PCB depends on several factors:

    • Copper thickness: Common values are 0.5oz, 1oz, or 2oz per layer.
    • Prepreg/Core thickness: Adjusted to achieve specific impedance and board height.
    • Number of plane vs signal layers: Affects thermal and mechanical behavior.

    Common Thickness Options:

    • 1.6mm (0.063″) – Industry standard, suitable for most applications.
    • 2.0mm to 2.4mm – Used when extra copper is needed for higher current.
    • 3.2mm or custom – Selected for industrial or military-grade boards.

    PCB Sizes:

    Panel sizes are typically 18” x 24” before routing. Your board can be as small as a few millimeters or as large as the full panel, depending on the application.

    6 Layer vs 8 Layer PCB

    A 6-layer PCB consists of six layers of copper circuitry stacked with insulating layers (prepreg and core) in between. It usually includes:

    • 4 Signal Layers for routing high- and low-speed signals
    • 1 Power Plane to distribute voltage
    • 1 Ground Plane to provide a return path and help with EMI suppression

    A typical 6-layer stackup looks like this:

    Layer 1: Signal (Top)

    Layer 2: Ground

    Layer 3: Signal

    Layer 4: Signal

    Layer 5: Power

    Layer 6: Signal (Bottom)

    While both 6-layer and 8-layer PCBs are widely used in advanced electronics, they serve slightly different purposes depending on design complexity, signal speed, and EMI requirements. Let’s compare them together:

    Aspect6-Layer PCB8-Layer PCB
    Layer Count68
    Typical Configuration4 signal layers + 1 power + 1 ground4 signal layers + 2 power + 2 ground
    Routing SpaceModerateMore routing room
    Signal IntegrityGood, suitable for most mid-speed signalsExcellent, supports very high-speed signal routing
    EMI ShieldingLimited shielding with fewer ground planesStrong EMI control due to multiple ground planes
    Power DistributionSingle power plane, higher impedanceDual power planes, better PDN performance
    Design ComplexityLess complex, easier to design and fabricateMore complex, better for advanced designs
    Thermal PerformanceAdequate for medium power applicationsBetter heat spreading for high-power components
    CostLower fabrication costHigher cost due to more layers and materials
    Use CaseMid-level MCUs, general embedded, basic RFFPGAs, DDR memory, high-speed data buses, complex SoCs

    Use a 6-Layer PCB if:

    • Your design isn’t extremely dense.
    • The signals don’t require tight EMI control.
    • You want to balance performance and cost.
    • There’s no strict need for multiple ground or power planes.

    It’s widely used in commercial electronics that don’t involve ultra-high-speed communication or compact multilayer routing challenges.

    Choose an 8-Layer PCB when:

    • High-speed signals (such as PCIe, USB 3.x, DDR4, or SERDES) are involved.
    • EMI performance is critical, especially in sensitive industrial or medical devices.
    • You need more space for routing due to a denser component layout.
    • Stable power delivery is required across multiple voltage domains.
    • You’re working with a compact form factor that demands vertical signal distribution.

    An 8-layer stackup allows designers to pair every signal layer with a nearby ground or power plane, which significantly improves signal quality and reduces noise.

    Benefits of Working with an Experienced PCB Manufacturer

    Designing and fabricating an 8-layer PCB stackup requires precise engineering and process control. Partnering with a reliable manufacturer like Best Technology brings several benefits:

    1. Stackup Design Assistance: Professional help with impedance control, signal integrity, and EMC optimization.

    2. Material Expertise: Guidance in choosing suitable laminates for your specific requirements.

    3. Advanced Fabrication: Capability to handle HDI, blind/buried vias, and tight tolerances.

    4. Quality Assurance: Rigorous testing like AOI, X-ray, and impedance measurement.

    5. Fast Turnaround: Efficient production process without sacrificing quality.

    Why Choose Best Technology for Your 8-Layer PCB Stackup?

    Best Technology is a trusted 8-layer PCB stackup specialist serving global customers across aerospace, medical, automotive, and industrial electronics. We hold certifications including:

    • ISO9001 for quality control
    • ISO13485 for medical electronics
    • IATF16949 for automotive-grade PCBs
    • AS9100D for aerospace applications

    Our engineers assist with DFM check, impedance control, EMI reduction, thermal management, and material choices, ensuring your 8-layer design performs reliably under real-world conditions.

    FAQs

    1. What is the best layer configuration for an 8-layer PCB stackup?

    A balanced configuration like Signal–GND–Signal–Power–GND–Signal–Power–Signal is often preferred for signal integrity and EMI control.

    2. How much does an 8-layer PCB cost?

    Cost varies by material, size, copper weight, and complexity, but typically ranges from $50 to $300 per board in small batches.

    3. What software is used for 8-layer PCB design?

    Tools like Altium Designer, Eagle, KiCAD, and OrCAD support multilayer PCB stackup planning and layout.

    4. Can you use HDI features in 8-layer PCBs?

    Yes. Blind and buried vias, via-in-pad, and microvias are often used in 8-layer HDI designs.

    5. How do I choose the right manufacturer for 8-layer PCBs?

    Look for certifications, material options, engineering support, and experience with multilayer stackups—like what Best Technology provides.