Archive for the ‘SinkPAD’ Category

What is the Value of the IMS PCB Structure for LED?

Monday, July 28th, 2025

IMS PCB structure plays a vital role in modern LED applications, especially where thermal management is critical. LEDs generate heat during operation, and poor heat dissipation can shorten their lifespan. That’s where IMS PCBs come in—they manage heat effectively while maintaining electrical performance. Let’s explore their structure, benefits, and how to choose the right solution for your needs.

Best Technology specializes in IMS PCB prototype, fabrication, assembly, and box build service. Our factory is equipped with automatic production lines, and the common lead time is shortened by 5 days. And we support 48 hours of prototyping. Moreover, we provide the ideal solutions from the DFM analysis to fabrication. Any doubts about the IMS PCB structure, just feel free to let us know at sales@bestpcbs.com.

What is the Value of the IMS PCB Structure for LED?

What is the IMS PCB Structure?

IMS stands for Insulated Metal Substrate, and its structure is designed to combine electrical performance with efficient heat dissipation. The IMS PCB structure is built from three key layers:

Copper Foil Layer – This top layer forms the conductive circuit and carries electrical signals with high reliability.
Dielectric Layer – Positioned between the copper and the metal base, this layer serves two vital roles: it provides electrical insulation and delivers high thermal conductivity, typically ranging from 1.5 to 8.0 W/m·K. This allows heat to pass quickly from the copper traces down to the metal base, protecting temperature-sensitive components like LEDs.
Metal Base Layer – Usually made of aluminum or copper, this bottom layer acts as a solid foundation and an effective heat sink, spreading and releasing heat away from the board.

Together, these layers create a structure that conducts electricity efficiently while also managing heat effectively, which is especially critical in LED lighting and power electronics. Unlike FR4 boards, IMS PCBs are purpose-built for applications where thermal control is crucial to performance and reliability.

What is the Difference Between IMS Circuit Board Structure and FR4 PCB?

Let’s compare IMS circuit boards and FR4 PCBs in terms of material and performance. FR4 PCBs use fiberglass-reinforced epoxy resin as the base, while IMS boards use a metal base. The insulation in IMS is thermally conductive but electrically resistant. Here’s a comparison table for better clarity:

Feature	IMS Circuit Board	FR4 PCB
Base Material	Aluminum or Copper	Fiberglass (FR4)
Thermal Conductivity	High	Low
Durability	Stronger for harsh use	Moderate
Cost	Higher initial, lower long-term	Lower initial

Clearly, IMS PCB structure offers better thermal performance, which is key for LEDs that must run cool and stable.

How Durable Is IMS Circuit Board in Harsh Environments Compared to FR4 PCB?

Durability is a major concern for LED applications in outdoor or industrial settings. IMS PCBs handle extreme temperatures, moisture, and mechanical stress better than FR4 boards. The metal base provides strength and stability, while the insulation resists breakdown. As a result, IMS circuit boards last longer and require fewer replacements, reducing maintenance costs. Many customers have faced early LED failures due to poor PCB durability—IMS technology solves this problem efficiently.

How to Select the Right Insulated Metal Substrate for Your IMS PCB Structure?

Choosing the right metal substrate depends on your specific needs. For standard LEDs, aluminum is common. For higher thermal demands, copper might be better. Also, consider the thickness of the metal base and dielectric layer. Thicker metal can handle more heat but adds weight and cost. Here’s a quick guide:

Aluminum: Affordable, good for most LED uses.
Copper: Higher thermal performance, higher cost.
Dielectric Layer: Choose based on thermal resistance (lower is better).

Working with an experienced IMS PCB manufacturer can help you make the right choice without wasting time or money.

What is the Manufacturing Process of IMS Board PCB?

Producing an IMS board PCB involves several precise steps to ensure thermal and electrical performance. Here’s how the process typically works:

Material Selection
The process begins by choosing the right metal base—usually aluminum or copper—based on thermal and mechanical needs.
Metal Base Preparation
The metal base is cleaned thoroughly to remove any contaminants. This ensures strong adhesion and consistent quality in the next layers.
Dielectric Layer Application
A high thermal conductivity dielectric layer is laminated onto the metal base. This layer provides insulation and helps transfer heat efficiently.
Copper Foil Lamination
Copper foil is then bonded to the top of the dielectric layer. This copper layer will form the conductive circuit paths.
Circuit Patterning
Using photoresist and chemical etching, the desired circuit design is created on the copper surface. This step must be precise to avoid defects.
Drilling
Holes for component placement or vias are drilled using automated equipment for accuracy and consistency.
Surface Finishing
A surface finish such as ENIG, OSP, or HASL is applied to protect the copper and improve solderability.
Testing and Quality Control
Each board undergoes electrical testing and thermal performance checks. Any defective board is removed to maintain high standards.

Best Technology controls every stage with care. As a professional IMS PCB manufacturer, Best Technology gains specialized knowledge in the MCPCB industry, and we have a stable, cutting-edge manufacturing process and strict quality control. Any inquiry about the material selection, IMS PCB structure, or any help with the IMS PCB project, pls let us know at sales@bestpcbs.com.

What is the Value of the IMS PCB Structure for LED?

The IMS PCB structure provides significant value in LED applications, especially where heat dissipation and reliability are critical. Many customers experience LED failure due to poor thermal design, leading to reduced brightness, shorter product life, and costly replacements. IMS PCBs address these issues effectively. Here’s how:

Superior Heat Dissipation
The most important value of IMS PCB structure is its ability to conduct heat away from the LED junction efficiently. The metal base combined with a high thermal conductivity dielectric (1.5–8.0 W/m·K) ensures heat is spread and released quickly. This prevents thermal buildup and keeps LEDs operating within safe temperatures.
Longer LED Lifespan
Overheating is a major cause of LED failure. By keeping temperatures low, IMS boards help extend the operating life of LEDs. This reduces maintenance needs and replacement frequency, especially in outdoor or industrial environments.
Stable Light Output
Temperature affects LED brightness and color stability. IMS PCB structure helps maintain consistent light output over time, which is essential for lighting applications in retail, automotive, or architectural sectors.
Compact and Lightweight Design
Because IMS boards handle heat so well, designers can reduce the size of heat sinks or eliminate them entirely. This allows for slimmer, lighter LED products without compromising performance.
Cost Efficiency Over Time
While IMS PCBs may have a higher initial cost than FR4, they offer long-term savings by reducing failure rates and minimizing heat-related damage. For high-power LED systems, IMS is a cost-effective solution.
Greater Reliability in Harsh Conditions
LEDs used in outdoor lighting, automotive, or factory settings must withstand vibration, moisture, and temperature changes. IMS PCBs provide mechanical strength and thermal stability, making them highly reliable in tough environments.
Fewer Failures, Higher Customer Satisfaction
Poor thermal design often leads to customer complaints and product returns. IMS technology helps companies deliver durable, high-performance LED products, increasing customer trust and reducing warranty claims.

In short, IMS PCB structure adds value by improving heat control, product durability, and design flexibility. For any LED application where efficiency and reliability matter, IMS is a smart and future-ready choice.

Why Choose Best Technology as Your Chinese IMS PCB Manufacturer?

Best Technology understands your concerns—slow delivery, poor quality, and unclear communication. We solve these headaches through the following strengths:

Customer Pain Point	Best Technology Solution
Delayed Delivery	Fast prototyping and strict lead-time management
Low Quality	Certified by ISO 9001, ISO 13485, IATF 16949, AS9100D, UL, RoHS; full quality checks
Unstable Supply Chain	Traceability with MES system and reliable sourcing
Technical Support Gaps	Professional engineers ready for design advice

With 19 years of experience, rigorous quality control, and responsive service, Best Technology is the right partner for your IMS PCB needs. From LED lighting to industrial controls, we deliver quality you can count on. For IMS PCB inquiry from prototype to assembly, pls let us know at sales@bestpcbs.com.

Tags:ims pcb structure
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What are the Pros and Cons for China IMS PCB vs PCB?

Thursday, July 24th, 2025

China IMS PCB offers a new level of thermal performance compared to standard PCB, and that is why it has become the top choice for power electronics and LED applications. But is it always better than traditional PCB? Let’s explore the answer in detail.

Best Technology is a reliable IMS PCB manufacturer and turnkey PCB Manufacturing service provider in China. We cater IMS PCB prototype, mass production, IMS PCB SMT assembly, and box build services in a truly free market. If you are looking for a decent quality China IMS PCB factory that is equipped with the cutting-edge manufacturing equipment and inspection apparatus, complete QC system, and strict test means, then Best Technology is the way to go. For specific IMS in PCB questions and inquiries, please email us from our Contact Us page on the website.

What are the Pros and Cons for China IMS PCB vs PCB?

What Does China IMS PCB Mean?

China IMS PCB stands for Insulated Metal Substrate PCB, manufactured by Chinese IMS PCB manufacturers. IMS PCB, also known as thermally conductive PCB, thermal PCB board, thermal Management PCB, and IMPCB.

In China IMS PCB, the circuit is built on a metal base, usually aluminum or copper. The core of IMS technology lies in its thermally conductive yet electrically insulating layer, which sits between the metal base and the copper circuit layer. This dielectric is usually filled with ceramic particles, allowing it to conduct heat efficiently while keeping the electrical signals isolated. The thermal conductivity of this insulating layer typically ranges from 1 to 3 W/m·K, but some advanced materials used in high-end applications can exceed 5 W/m·K. Besides ceramic-filled materials, some IMS boards use advanced polymer-based insulating layers, which offer flexibility in thickness and can be tailored for specific thermal or electrical needs.

This design improves heat dissipation and structural strength. Unlike regular PCB made of FR4 material, IMS boards handle higher power loads with ease. Many China-based factories now focus on IMS production due to the growing demand in automotive, LED, and industrial sectors.

Who Are the Best China IMS PCB Manufacturers?

Choosing the right manufacturer can affect quality and cost. Best Technology is a trusted name for China IMS PCB. We follow IPC standards, apply MES systems for traceability, and offer real-time quality monitoring. Our strength lies in custom thermal design, fast delivery, and flexible order sizes. Other reputable suppliers include A-Tech Circuits and JLCPCB.

What Is China IMS PCB Price?

The price of China IMS PCB depends on more than just size. Materials, design complexity, and special processing all affect the cost. Below is a detailed explanations to help you understand the key pricing factors.

1. Material Type

Aluminum-Based IMS PCB: This is the most common choice due to its balance of cost and thermal performance. A 1.5mm thick aluminum IMS board typically costs around $0.20 per square inch.
Copper-Based IMS PCB: Provides better thermal conductivity and durability, especially for harsh environments, but usually costs 1.5 to 2 times more than aluminum-based boards.
Dielectric Layer: Thermal insulation materials filled with ceramic or polymer vary in price. High-conductivity dielectrics (>3 W/m·K) cost more than standard ones.
Specialty Fillers: Advanced options like boron-filled dielectrics offer improved thermal stability but increase material cost by 10%–25%, depending on the formulation.

2. Thickness and Size

Thicker Metal Cores (>2mm): These require more raw material and longer machining time, raising both material and processing costs.
Larger Panel Size: Increases raw material use and slows production speed, slightly raising the per-unit price.

3. Layer Count

Single-Layer IMS PCB: Most cost-effective; ideal for heat-sensitive, low-complexity designs.
Double or Multi-Layer IMS PCB: Involve complex bonding and precision drilling, which increases both material cost and labor. These are 10%–30% more expensive than single-layer versions.

4. Surface Finish and Special Processing

Surface Treatments: Options like ENIG or OSP add to the price. ENIG, for instance, offers better corrosion resistance but is costlier than basic HASL finishes.
Diamond Cutting: Needed for clean edge finishes on thicker metal cores. This adds a processing premium of around 5%–10%.
Solder Mask Type: High-temperature solder masks or UV-curable masks may also increase pricing slightly.

5. Comparison to FR4 PCB

On average, China IMS PCB cost is 20%–50% higher than standard FR4 PCBs of similar dimensions.
For example, a 1.5mm FR4 board might cost $0.10 per square inch, but lacks the heat handling and strength of IMS.
The additional cost is often offset by the longer lifespan and reduced maintenance of IMS in demanding applications.

6. Order Volume

Prototype Orders: Most Chinese suppliers allow no MOQ and quick turnaround for prototypes.
Small Batch Orders: May include engineering setup fees ($20–$50) for design validation and tooling.
Mass Production: Larger orders reduce cost per unit. Many suppliers offer tiered pricing, with better rates for orders over 1,000 units.

7. Value in High-Power Applications

IMS PCBs perform better under thermal stress, so they reduce failure rates in power electronics, LEDs, and automotive systems.
The higher upfront cost often pays off through longer service life and fewer field failures.

In summary, when assessing China IMS PCB price, it’s important to consider material type, layer count, special processing like boron-filled insulation, and order size. While IMS boards cost more than FR4, they deliver better thermal performance and reliability, especially in power-hungry designs. Over time, this can reduce maintenance costs and improve product lifespan—making IMS a smart investment for many applications.

Why Do I Need China IMS PCB?

Thermal control is key in electronics. IMS in PCB helps to reduce heat buildup, which protects components and maintains performance. Applications such as LED lighting, power supplies, and EV chargers often generate excess heat. In these cases, using China IMS PCB can prevent failure. Also, the mechanical strength of metal-core boards improves vibration resistance. If your design needs better heat flow, IMS is worth the extra cost.

What Is the Difference: China IMS PCB vs PCB?

The main difference is in material and thermal performance. Standard PCB uses FR4, a fiberglass material, while IMS uses metal cores. FR4 PCBs have low heat conductivity (0.1 to 0.5 W/m·K), but IMS boards range from 1 to 12 W/m·K. This makes China IMS PCB ideal for high-power systems. However, IMS is less flexible in multilayer designs and costs more. On the other hand, FR4 is cheaper and easier for complex routing. So the choice depends on the application.

What Are the Pros and Cons for China IMS PCB vs PCB?

Here is a clear view of the pros and cons:

Pros of China IMS PCB

Superior Thermal Control: Prevents overheating and extends component life.
High Mechanical Strength: Reduces warping and improves durability in harsh environments.
Ideal for Power Applications: Handles high currents with minimal heat rise.
Better Heat Flow: No need for thermal vias, direct heat spread through metal core.

Cons of China IMS PCB

Higher Cost: Material and tooling cost more than FR4 PCB.
Limited Layer Count: Not suitable for complex, multilayer circuits.
Thermal Stress Risks: Poor bonding or design can cause delamination in low-quality boards.

Why Choose Best Technology as Your Dependable IMS PCB Manufacturer?

At Best Technology, we understand the headaches customers face when sourcing China IMS PCB. Poor thermal design, weak bonding, and long lead times can all lead to delays and failure. We solve these with:

Thermal Simulation Support: We offer thermal modeling to guide your design and prevent hotspots.
Advanced Materials: Our boards use hybrid cores and optimized dielectrics to improve heat flow and reduce stress.
Reliable Production: Our MES system ensures traceability, and all boards pass IPC-compliant testing like thermal cycling. And all the fabrication process is in line with ISO 9001, ISO 13485, IATF 16949, AS9100D, UL, REACH, RoHS.
Flexible Orders: We support no-MOQ prototypes and offer higher quality mass orders with short lead time.
Application-Specific solutions: As we have 19 years of accumulation in the rapidly evolving world of electronics, you will get the benefits from our rich experience and technical knowledge to help you choose between FR4/IMS and get an ideal solution.
Expert Support: From quoting to delivery, our engineers assist you in every step, ensuring clear communication and fast turnaround.

Our clients appreciate not only our quality but also our commitment to problem-solving. With China IMS PCB, success is in the details, and we handle those with care.

Why Choose Best Technology as Your Dependable IMS PCB Manufacturer?

To sum up, China IMS PCB brings real advantages in heat management, mechanical strength, and durability. While it comes at a higher cost, the benefits often justify the price in high-power settings. However, design and manufacturing skills make a significant difference.

That’s why working with Best Technology gives you ‌unmatched precision, reliability, and cutting-edge solutions tailored to your needs.‌ Our thermal modeling, strict quality control, and fast delivery remove the usual risks. So if you need reliable IMS PCB solutions, contact us today for a quote. Our engineers are very responsible, caring, professional, experienced, and knowledgeable. They were always available to discuss your case and have returned your phone calls in a timely manner. Please discuss your full requirements with our teams at +86-755-2909-1601 or sales@bestpcbs.com.

Tags:China IMS PCB, China ims pcb vs pcb
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IMS PCB Definition: 3 Key Focus & 80% Better Thermal

Tuesday, July 22nd, 2025

IMS PCB definition refers to a printed circuit board built on an Insulated Metal Substrate, primarily designed for excellent heat dissipation. This structure supports high-power components and keeps temperatures under control. While many boards rely on FR4, IMS stands out where thermal stress is high.

Best Technology is a top-tier IMS PCB manufacturer and PCBA service provider in China. Since 2006, we have gained great first-hand experience in dealing with thermal management challenges in customers’ compact designs and providing full solutions to customers for their inadequate heat dissipation in high-power applications. Our factory has passed certifications like ISO 9001, ISO 13485, IATF 16949, AS9100D. Our factory has the full qualification to manufacture reliable IMS PCBs and PCBA to the market.

IMS PCBs stand out through their metal-core structure, thermal dielectric layer, and suitability for high-power applications—delivering up to 80% better heat dissipation than FR4. If you have any doubts about the IMS PCB definition or you require more advice from us, please make a call to +86-755-2909-1601 or send your Gerber file and special requirement details to us at sales@bestpcbs.com.

IMS PCB Definition: 3 Key Focus & 80% Better Thermal

What is IMS PCB Definition?

To understand the IMS PCB Definition, we need to break it down into three main aspects:

Metal-core construction: IMS PCBs use a metal base such as aluminum or copper. This helps draw heat away from components faster than FR4 materials.
Thermal dielectric layer: Between the copper circuitry and the metal base lies a special dielectric layer, usually 0.05–0.20mm thick. This layer balances electrical insulation and thermal conductivity.
High-power applications: IMS PCBs are built for products that produce significant heat like LEDs, power modules, and automotive electronics. Their construction makes them dependable even under high thermal load.

When these three focus areas are optimized, the thermal performance of IMS PCB can reach up to 80% better than FR4 PCBs. This is due to the metal base’s superior conductivity and the efficient stack-up structure. In short, IMS PCB is engineered for reliability in thermally demanding environments.

What Are the Types of IMS PCB?

There are mainly two types based on the base metal: Aluminum-based IMS PCB and Copper-based IMS PCB. IMS PCBs (Insulated Metal Substrate PCBs) come in several types depending on their structure and application needs. Each type offers unique benefits to match specific electrical, thermal, and mechanical demands. Here are the most common ones:

1. Flexible Aluminum IMS PCB
This type uses a flexible dielectric layer combined with aluminum alloys such as 5754. It can bend and conform to curved surfaces without cracking, making it ideal for wearable devices, foldable modules, or curved LED lighting. The flexibility doesn’t sacrifice thermal performance, which makes it suitable for tight and dynamic installation spaces.

2. Hybrid Aluminum IMS PCB
Hybrid types combine traditional FR4 multilayer cores (like 2-layer or 4-layer boards) with an aluminum base using thermally conductive adhesives. This structure lowers cost while still improving heat dissipation over standard FR4. It’s commonly used in RF applications or areas that need better EMI shielding along with moderate thermal control.

3. Multilayer Aluminum IMS PCB
Designed for high complexity systems, this type stacks multiple dielectric layers and may include blind vias or thermal vias. It supports dense circuit routing, power management, and thermal paths within the same board. Applications include industrial power supplies and advanced motor controls where both thermal and signal integrity are critical.

4. Through-Hole Aluminum IMS PCB
Here, the aluminum base acts as a mechanical and thermal “core” for multilayer construction. Plated through holes enable either full electrical connection or insulation, depending on design. This type is well-suited for high-current modules, including automotive charging systems or power converters, where mechanical strength and efficient heat transfer are equally important.

5. Copper-Based IMS PCB
Instead of aluminum, this version uses copper (like C1100) as the metal core, offering much higher thermal conductivity—around 400 W/m·K. Though more expensive, copper IMS PCBs are unmatched in heat management and are often used in extreme environments, such as high-frequency power electronics, laser systems, or high-intensity LED drivers.

What Are the Common Thicknesses of Copper Substrate IMS PCB?

Copper thickness matters in heat spreading and current capacity. Common thicknesses are:

1 oz (35μm) – standard, used in most designs
2 oz (70μm) – better for power and thermal needs
3 oz to 6 oz – for heavy-duty applications

Choosing the right copper thickness balances cost, weight, and performance. It depends on the device’s power level and thermal load.

What is a FR4 PCB in Electrical Terms?

FR4 PCB uses a glass-reinforced epoxy laminate as the core. It is widely used due to its low cost and electrical stability. But it is not built for heat-heavy conditions. FR4 struggles when components generate high thermal energy. Let’s take a closer look at its detailed features.

1. Material and Structure
FR4 stands for “Flame Retardant level 4,” a UL94 V-0 rated material that self-extinguishes when ignited, enhancing electrical safety. The board is constructed by laminating layers of glass fiber for mechanical strength and epoxy resin for electrical insulation. This results in a durable, uniform substrate that supports multi-layer circuit builds.

2. Electrical Properties
One of the main reasons FR4 remains a popular choice is its reliable electrical insulation. It provides an insulation resistance between 10¹² to 10¹⁵Ω, effectively separating circuit paths.
Key dielectric characteristics include:

Dielectric constant (Dk) between 4.0 to 4.7 – this affects how fast signals move through the PCB.
Dissipation factor (Df) between 0.01 to 0.03 – indicating low signal loss, suitable for medium to high-frequency applications.
These properties help maintain signal clarity, especially in digital and RF circuits.

3. Thermal and Mechanical Performance
FR4 PCBs generally operate within a temperature range of 130°C to 180°C, which covers most consumer and industrial electronics.
They also exhibit excellent mechanical stability, showing minimal warping under humidity or temperature fluctuations. This consistency makes FR4 a solid choice for high-precision multilayer PCB manufacturing.

4. Manufacturing and Application Benefits

Cost-Effective: FR4 is one of the most affordable and widely available materials. Its mature production process supports mass production with consistent results.
Good Workability: It can be easily cut, drilled, and etched to fit complex layouts, which speeds up prototyping and full-scale fabrication.
Versatile Applications: It’s used in everything from mobile phones and computers to control boards, sensors, and consumer electronics.

However, when the circuit involves high power or heat—such as in LED drivers, automotive modules, or power converters—FR4 may fall short in thermal performance. In those cases, materials like IMS offer better thermal conductivity and system reliability. IMS PCB transfers heat 80% faster than FR4 in many setups.

Material	Thermal Conductivity (W/mK)	vs. FR4
FR4	0.1–0.5	Baseline
IMS Dielectric	1.0–12.0	8–12× higher
Aluminum Core	~200	400–1000× higher
Copper Core	~400	800–1600× higher

Why is IMS Needed?

Electronics are smaller, faster, and more powerful. This generates more heat in tighter spaces. FR4 boards can’t always manage that heat. When parts overheat, performance drops or fails entirely. IMS provides a way out. It pulls heat away from hot spots and extends product life. It keeps temperatures low and improves reliability.

Also, IMS helps reduce the size of heatsinks or external cooling. This saves space and weight, especially in automotive and lighting systems.

What Factors Affect the Quality of Thermal Separation IMS PCB?

Several key elements decide how well IMS handles heat:

Dielectric Layer Quality: The thinner and more thermally conductive the layer, the better the heat transfer.
Copper Thickness: More copper helps move heat faster.
Metal Base Type: Copper performs better but costs more.
Bonding Strength: A strong bond between layers ensures stable performance and durability.

At Best Technology, we keep strict control over each of these steps. We use advanced testing tools like TDR and thermal shock tests to validate heat performance and bonding quality.

Why Choose Best Technology as Your Major IMS PCB Manufacturer?

Customers face real concerns when sourcing IMS PCBs. Some suppliers deliver inconsistent quality. Others delay shipments or use low-grade raw materials. These issues cost time and damage trust.

Best Technology solves these headaches:

Traceability: Every board’s raw material can be traced through our MES system. This avoids counterfeit risks.
Certifications: We hold ISO 9001, ISO 13485 for medical, IATF 16949 for automotive, and AS9100D for aerospace. This proves our strict quality control.
Stable Lead Time: We stick to schedules, even in tight demand cycles. Our in-house capacity and vendor network help achieve this.
Engineering Support: From DFM checks to prototype validation, our team gives solid advice and practical solutions.
Full Solutions: We support a rich product line, such as IMS PCB, MCPCB, rigid, flex, rigid-flex, ceramic PCBs, and PCBA. Whatever substrate you need, such as FR-4, high Tg FR-4, halogen-free FR-4, metal core, copper core, ceramic, Low Dk/Df (ISOLA/ Rogers), our engineers have extensive experience to suggest viable PCBs for your projects.

We also offer fast prototype runs for new designs and flexible batch sizes for scale-up plans. That gives you agility in product launch and market testing.

Why Choose Best Technology as Your Major IMS PCB Manufacturer?

In a nutshell, IMS PCB definition covers more than just structure—it’s about thermal efficiency, product lifespan, and system safety. With up to 80% better heat transfer than FR4, IMS PCBs have become the backbone of high-power, compact electronics. Choosing the right thickness, base metal, and supplier could increase your company’s competitive edge in the marketplace.

Partnering with Best Technology means fewer delays, better quality, and a team that knows what you need. We understand the real challenges you face, and we deliver real solutions. For any quotes, please contact us at sales@bestpcbs.com or call +86-755-2909-1601.

Tags:Ims pcb definition
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What is DTP MCPCB? DTP Copper MCPCB Structure

Wednesday, June 25th, 2025

A DTP MCPCB, or Direct Thermal Path Metal Core PCB, also known sinkpad MCPCB, is a type of printed circuit board designed for high-power and high-heat applications. It helps electronics stay cool and stable, even under heavy loads. Compared to standard MCPCBs, DTP PCBs offer better thermal transfer and stronger mechanical support. Many industries, including LED, power supply, automotive, and telecom, now prefer DTP copper MCPCBs for reliable performance.

In this blog, we’ll explain what DTP means, its features, structure, design tips, manufacturing process, and how it fits into modern electronics.

What Is DTP and Its Features?

DTP stands for Direct Thermal Path. It refers to a design where heat moves directly from hot components to the metal base without many thermal barriers. This path lowers thermal resistance and keeps components cooler.

Main Features of DTP:

Direct connection between heat source and metal base
Higher heat dissipation than traditional MCPCBs
Stronger thermal conductivity through thick copper or copper convexity
Better reliability in high-power circuits
Long-lasting even under thermal cycling and vibration

This structure reduces the chance of overheating, which helps the whole system run longer and safer.

DTP Copper MCPCB Structure

A DTP copper MCPCB uses a raised copper structure (called a copper convexity or copper boss) formed directly on the metal base. This convex feature aligns under the heat source, typically a power component like a MOSFET or high-wattage LED. The DTP copper PCB layers are:

Top Layer: Copper trace for electrical routing
Dielectric Layer: High thermal conductivity insulation
Copper Convexity: Directly contacts both the component and the base
Metal Base: Usually aluminum or copper for heat spreading

Its stackup layers is:

This design bypasses traditional insulation layers and allows heat to flow directly into the metal core.

DTP MCPCB vs Traditional MCPCB

Standard MCPCBs have a thin dielectric layer between the copper trace and the metal base. This layer adds thermal resistance. In contrast, a DTP PCB reduces this resistance by forming a direct path between the component and the base metal using copper convexities.

Feature	DTP MCPCB	Traditional MCPCB
Heat Transfer	Direct (through copper convexity)	Through dielectric
Thermal Resistance	Very Low	Medium
Use Case	High-power, LED, EV, power supply	General LED, moderate power
Cost	Higher	Lower
Performance	Excellent	Good

Where Are DTP PCBs Used?

DTP MCPCBs are perfect for any application where heat is a big issue. They’re now standard in many thermal-critical products. The main applications including:

High-power LED lighting
Power supplies and inverters
Electric vehicles (EVs) and battery packs
RF and telecom base stations
Solar energy systems
Laser modules and sensors

Whenever components get hot and space is tight, DTP copper MCPCBs offer a smart solution.

Tips for MCPCB Design with DTP Structure

Designing a DTP PCB requires special attention to thermal paths, layout, and material selection.

Place heat-generating components directly over copper convexities
Use high-conductivity dielectric materials to keep thermal resistance low
Align thermal vias with component pads for effective heat flow
Choose a suitable base material: aluminum for cost, copper for performance
Ensure planarity and flatness for solid thermal contact

A carefully designed DTP MCPCB handles more power without compromising safety or reliability.

Why Is the Price of DTP MCPCB Higher Than a Normal MCPCB?

The cost of a DTP MCPCB is higher due to the complexity of its design and processing. It uses thicker copper or custom copper convexities, which are more expensive than standard copper foil. Creating a precise raised copper feature under each heat source requires extra machining steps, tight alignment, and rigorous quality checks.

Additionally, the dielectric materials used must have very high thermal conductivity and are usually more costly. The manufacturing process also involves advanced methods like X-ray alignment, CNC machining, and thermal performance testing. Despite the higher price, DTP MCPCBs offer long-term savings by improving thermal efficiency, reducing failure rates, and extending product lifespan.

How DTP MCPCBs Are Manufactured?

The manufacturing of a DTP MCPCB is more advanced than a standard MCPCB manufacturing process. It focuses on forming a raised copper boss (convexity) that provides a one-piece thermal bridge between the heat source and the metal base.

1. Base Metal Preparation

The aluminum or copper base is cleaned and pre-treated. This forms the foundation for the entire board.

2. Creating the Copper Convexity

A raised copper feature is formed on the base metal. This copper boss is placed directly beneath high-heat components. The convexity may be CNC machined or created during the copper plating process.

3. Dielectric Layer Lamination

A thin, high-thermal-conductivity dielectric is laminated around the copper convexity and onto the metal base. The copper bump remains exposed to make direct contact with the top copper circuit.

4. Copper Foil Application & Circuit Etching

Copper foil is laminated onto the surface and patterned using photolithography. The exposed part of the copper boss connects directly to a pad on the top layer.

5. Drilling & Plating (if required)

If the design includes signal vias or multi-layer connections, micro-drilling and copper plating are applied carefully to avoid damaging the copper boss.

6. Solder Mask & Surface Finish

Solder mask is printed, leaving heat transfer pads exposed. Surface finish (e.g., ENIG, HASL) is applied for soldering protection.

7. Inspection & Testing

X-ray confirms alignment of copper convexity under the pad
Thermal resistance is measured
Electrical continuity is tested
Visual and mechanical checks ensure no delamination or defects

This process requires tight process control and high-end fabrication equipment.

Benefits of Using DTP Copper MCPCB in High-Power Electronics

Superior thermal performance for high-wattage components
Longer component life due to reduced junction temperatures
Smaller form factor with higher power density
Stable performance under vibration, shock, and thermal cycling
Improved system efficiency and lower cooling requirements

These benefits make DTP MCPCBs an excellent investment for demanding applications.

DTP PCB Material Choices

A high-quality DTP PCB relies on the right materials:

Copper Convexity: Pure copper, usually 1–4mm thick
Dielectric Layer: Ceramic-filled epoxy or other high-conductivity material

Metal Base:

Aluminum: Lightweight, good for general use
Copper: Best thermal conductivity, ideal for extreme conditions

The right combination depends on your project needs, thermal limits, and cost targets.

Why Work With a Reliable DTP MCPCB Manufacturer?

Not all PCB manufacturers can build DTP MCPCBs. You need a supplier with tight process control, CNC machining, and advanced lamination tools.

A good DTP supplier should offer:

Custom DTP MCPCB design support
In-house thermal simulation and analysis
CNC or stamping for copper convexity
X-ray and AOI for high-precision quality control
Quick prototyping and scalable volume production

About Best Technology

At Best Technology, we are experts in DTP MCPCBs, aluminum PCBs, and thermal solution boards. We serve industries including LED, automotive, telecom, and medical electronics. We also use MES systems to provide full traceability of materials and processes. Our team can support you from design to mass production with reliable engineering and fast service.

Call To Action

If you’re working on a demanding project, contact Best Technology to learn how a custom DTP copper MCPCB can power your next innovation.

FAQs

1. What is a DTP MCPCB?

A Direct Thermal Path MCPCB uses a raised copper convexity to transfer heat directly from the component to the metal base.

2. How does a DTP copper MCPCB differ from a standard one?

It bypasses insulating layers by forming a direct copper path, reducing thermal resistance.

3. What are the main uses of DTP PCBs?

Used in LED lighting, power supplies, automotive electronics, and telecom base stations.

4. Why is the DTP MCPCB more expensive?

It uses more copper, complex machining, high-end materials, and tighter quality control.

5. Does Best Technology offer custom DTP MCPCB services?

Yes, we provide full engineering support, fast prototyping, and scalable production.

Tags:dtp mcpcb
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Direct Thermal Path Copper PCB Manufacturer

Wednesday, June 4th, 2025

What Is Direct Thermal Path Copper PCB?

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

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

Direct Thermal Path Copper PCB Manufacturer

Why Thermal Management Matters in Electronics?

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

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

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

Features of DTP Copper PCB

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

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

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

How Does DTP PCB Work?

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

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

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

How Does the Convexity Pad Create?

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

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

Why Aluminum Base Is Not Suitable to Make DTP PCB?

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

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

Considerations While Using Direct Thermal Path MCPCB

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

1. Component Placement

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

2. Base Thickness

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

3. Thermal Simulation

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

4. Dielectric Material

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

5. Mounting & Enclosure

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

6. Surface Finish

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

DTP Copper PCB Manufacturing Process

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

Step 1: Base Metal Selection

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

Step 2: Lamination

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

Step 3: Circuit Layer Preparation

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

Step 4: Dielectric Removal

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

Step 5: Convex Pad Formation

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

Step 6: Surface Finishing

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

Step 7: Solder Mask and Silkscreen

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

Step 8: Testing and Quality Control

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

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

Common Applications of DTP MCPCB

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

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

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

FAQs About Direct Thermal Path MCPCB

Q1. What makes DTP PCBs different from regular MCPCBs?

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

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

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

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

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

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

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

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

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

Tags:direct thermal path copper pcb, direct thermal path pcb, dtp pcb
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What is IMS PCB? IMS PCB Stack-up

Wednesday, June 4th, 2025

What is IMS PCB?

IMS PCB stands for Insulated Metal Substrate Printed Circuit Board. It’s a specialized type of PCB designed to manage heat more effectively than standard boards. At its core, an IMS board is made of three main layers: a metal base (usually aluminum), a thermally conductive dielectric layer, and a copper circuit layer on top.

This unique construction gives IMS boards exceptional heat transfer capabilities. Unlike standard FR4 boards, where heat may accumulate and degrade performance over time, an IMS PCB actively channels heat away from components and dissipates it through the metal base. This process helps protect sensitive parts and improves overall device longevity.

IMS PCBs are commonly used in LED lighting systems, power converters, automotive electronics, solar inverters, and industrial control systems. Any circuit that generates significant heat can benefit from the enhanced thermal management of an IMS PCB.

Features of IMS PCB

IMS PCBs are favored in demanding applications because of their distinct advantages. Below are some of the standout features:

1. The dielectric layer in an IMS PCB has much higher thermal conductivity compared to FR4.

2. Once heat reaches the metal base, it is dispersed across a larger surface area or transferred to a heatsink.

3. The metal base not only helps with heat but also strengthens the board. This added rigidity reduces the chances of warping, especially in environments with temperature cycling or mechanical stress.

4. Components perform better and last longer when they remain within optimal temperature ranges.

5. Most IMS boards are single-sided, simplifying the layout and making them easier to manufacture. However, advanced designs may include multilayer configurations when required.

6. The metal base can also serve as a shield against EMI interference, which is useful in sensitive analog or RF applications.

Types of IMS Boards

Different IMS boards are used for different applications depending on the metal type and overall construction. Here are the three primary types:

Aluminum-Based IMS PCB

This is the most popular type and often the first choice for LED lighting and consumer electronics. Aluminum is lightweight, affordable, and has decent thermal performance. It strikes a balance between cost and functionality for a wide range of applications.

Copper-Based IMS PCB

Copper has better thermal and electrical conductivity than aluminum. These boards are used in high-end applications where superior thermal management is critical, such as power modules, solar inverters, and automotive control systems. However, copper is more expensive and heavier than aluminum.

Steel-Based IMS PCB

Less common but useful in environments where mechanical durability is crucial. Steel doesn’t conduct heat as efficiently as copper or aluminum but provides maximum rigidity and resistance to deformation. It’s mainly used in industrial or military electronics.

Each type of IMS PCB is selected based on the specific needs of your project. Aluminum offers a good starting point, copper pushes performance higher, and steel provides strength for the harshest conditions.

IMS PCB Stack-up

A critical element in IMS board design is the stack-up, which refers to how the different layers of the board are arranged. The typical IMS PCB stack-up includes the following:

1. Copper Layer

This is where all the electronic traces and pads are formed. The copper thickness usually ranges from 1 oz to 3 oz per square foot, depending on current requirements. It serves as the pathway for electrical signals and power.

2. Dielectric Layer

This is the thermally conductive but electrically insulating layer that separates the copper and the metal base. It’s usually made of a polymer filled with ceramic particles. The dielectric plays a vital role in transferring heat efficiently while preventing short circuits. The thickness typically ranges from 0.075 mm to 0.2 mm, with thermal conductivity from 1 to 7 W/m·K, depending on material grade.

3. Metal Base

This is typically made of aluminum, copper, or steel. The metal provides mechanical support and acts as the main heat dissipation path. Its thickness usually ranges from 1 mm to 2 mm, but thicker bases are used in heavy-duty applications.

Some advanced designs may include additional dielectric and copper layers to create double-layer or multilayer IMS PCBs, though this increases cost and complexity.

How Thick is an IMS PCB?

The total thickness of an IMS PCB is influenced by the materials used and application requirements. On average, the board thickness ranges from 0.8 mm to 3.2 mm, but custom configurations are available.

Here’s a breakdown of each layer’s contribution to overall thickness:

Copper Layer: 35–105 µm (1–3 oz)
Dielectric Layer: 75–200 µm
Metal Base Layer: 1.0–2.0 mm (for aluminum or copper)

Applications requiring high current typically demand thicker copper layers and sometimes thicker base metals. Likewise, if better insulation is needed, the dielectric layer can be made thicker, but this may reduce heat transfer efficiency. Engineers must balance electrical, thermal, and mechanical requirements to define the most suitable thickness.

What is the Difference Between IMS PCB and FR4 PCB?

Though both are used in electronic devices, the differences between IMS PCB and FR4 PCB are quite substantial:

Parameter	IMS PCB	FR4 PCB
Full Name	Insulated Metal Substrate PCB	Flame Retardant Grade 4 PCB
Base Material	Metal core (usually aluminum or copper)	Fiberglass-reinforced epoxy (FR4)
Thermal Conductivity	High (1–7 W/m·K, depending on dielectric)	Low (typically 0.3–0.4 W/m·K)
Heat Dissipation	Excellent, through metal base	Limited, requires heatsinks or fans
Layer Structure	Usually single-sided	Can be single, double, or multilayer
Mechanical Strength	High (due to metal base)	Moderate (flexible but less rigid)
Weight	Heavier (due to metal core)	Lighter
Manufacturing Cost	Higher	Lower
Applications	Power electronics, LEDs, automotive, solar	Consumer electronics, IoT, communication devices
Thermal Resistance	Low (better heat flow)	High (poor thermal path)
Electrical Insulation	Through thermally conductive dielectric	Provided by FR4 material itself
Common Copper Thickness	1–3 oz	1–2 oz
Typical Board Thickness	0.8–3.2 mm	0.6–2.0 mm
Design Complexity	Lower (usually single-layer)	Higher (multilayer and complex routing possible)
Price Range	Mid to High	Low to Mid

What is the Thermal Resistance of IMS Board?

Thermal resistance (Rθ) refers to a material’s resistance to heat flow. In IMS PCBs, it is mainly influenced by the dielectric layer. A lower Rθ means better heat transfer and lower temperature rise.

The thermal resistance of an IMS board is calculated using:

Rθ = t / (k × A)

Where:

t = dielectric thickness

k = thermal conductivity

A = surface area

Typical values for IMS PCBs range from 0.2°C/W to 1.0°C/W, depending on materials and layout. Advanced dielectric materials with high k-values can push this number lower, helping improve performance in high-power applications.

Designers often select materials with k ≥ 3 W/m·K and limit the dielectric layer to under 150 µm to achieve low thermal resistance.

Best Technology – Reliable IMS PCB Manufacturer

If you’re sourcing IMS PCBs and want consistent quality, Best Technology is your go-to IMS PCB manufacturer. We have a dedicated production line for metal-core PCBs, including aluminum, copper, and hybrid metal boards.

Why Choose Best Technology?

✅ Professional Engineering Support: Our experienced team helps optimize stackups, select dielectric materials, and improve thermal paths in your layout.

✅ ISO Certifications: We are certified with ISO9001, IATF16949, ISO13485, and AS9100D, serving a wide range of industries including medical, automotive, and aerospace.

✅ MES Traceability: Every board is tracked using our MES system to ensure complete traceability from raw materials to final shipment.

✅ Flexible Volumes: Whether you need a prototype batch or full-scale production, we offer scalable solutions.

✅ Comprehensive IMS PCB Assembly: Beyond PCB fabrication, we also offer full assembly including component sourcing, reflow soldering, inspection, and testing.

From concept to finished product, we work closely with clients to deliver high-performance IMS PCBs that meet electrical, mechanical, and thermal demands.

FAQs

1. What does IMS PCB stand for?

It stands for Insulated Metal Substrate Printed Circuit Board, a high-performance board for heat-sensitive applications.

2. Can IMS PCB be double-sided?

Yes, though less common. Double-sided IMS PCBs require more advanced fabrication and cost more, but they’re available for complex designs.

3. Is IMS PCB good for automotive systems?

Absolutely. Automotive systems generate a lot of heat and require reliability. IMS PCBs are ideal for ECUs, power converters, and headlight controls.

4. What thermal conductivity should I choose for my dielectric layer?

It depends on the heat generated. For moderate power, 1–2 W/m·K is enough. For high-power LEDs or power modules, choose ≥3 W/m·K.

5. How do I request a quote from Best Technology?

Send your Gerber files, stackup requirements, and assembly needs to our team, and we’ll respond with a customized quote within 24 hours.

Tags:Ims pcb assembly, Ims pcb definition, Ims pcb manufacturer
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Copper Core PCB vs Aluminum PCB: How to Choose the Right One? – Series 2

Saturday, May 24th, 2025

In our last blog, we introduced the definition and basic of copper core PCB. But copper core PCB isn’t the only one metal core PCB, aluminum PCB provides good heat dissipation as well. So, when working with metal core boards, many engineers and buyers are unsure whether to choose an aluminum PCB or a copper core PCB. Some believe copper is always better, while others go with aluminum for lower cost. Today, we will guide you how to choose them, then let’s start it!

Material Comparison: Copper vs Aluminum Core

Both copper and aluminum are used as the core material for thermal management in PCBs, but their physical and electrical properties differ significantly:

Property	Copper	Aluminum
Thermal Conductivity	~380–400 W/m·K	~200–230 W/m·K
Electrical Conductivity	~58 MS/m	~35 MS/m
Density	8.96 g/cm³	2.70 g/cm³
Strength	Higher rigidity	More flexible
Cost	1.5x to 3x higher	Lower

Copper provides superior conductivity and better rigidity but comes at a much higher cost and weight. Aluminum is lighter, easier to machine, and cost-effective for mid-range applications.

Thermal Management: Which One Handles Heat Better?

When heat dissipation is your top priority, copper clearly wins. Its high thermal conductivity allows heat to spread faster and more evenly, which is critical in high-power applications like:

LED floodlights and stadium lighting
Automotive headlights
Power converters and inverters
Laser driver modules

Case example: A customer replaced an aluminum PCB with a copper base for a 100W LED driver. The operating temperature dropped by 15°C, drastically improving product lifespan.

However, in low-to-mid power systems—like ceiling lights, LED bulbs, or camera light rings—aluminum is typically sufficient. Using copper in these cases is often unnecessary and drives up costs without clear benefits.

Copper Core PCB vs Aluminum PCB: How to Choose the Right One? - Series 2

Mechanical Strength and Weight: What Does Your Design Need?

Copper core PCBs are heavier and more rigid, which makes them better for industrial applications exposed to vibration or extreme temperature cycles.

But in products where weight matters—like drones or wearable devices—aluminum PCBs are the smarter option. They are easier to machine, route, and assemble. They also cost less in terms of tooling and manufacturing time.

Choose copper core PCBs if you need:

High mechanical stability
Vibration resistance
Long-term thermal durability

Choose aluminum PCBs if your product needs:

Lightweight design
Cost control
Simpler routing and drilling

Cost Consideration: Is Copper Always Worth It?

Let’s be honest: copper core PCBs can cost up to 3x more than aluminum PCBs. So you should ask yourself—is the higher thermal performance really necessary for your design?

Aluminum PCBs are the better choice when:

Your application doesn’t exceed 80W–100W
Weight and cost are design priorities
You’re in mass production and need price stability

Copper core PCBs are justified when:

Your system needs to handle heavy heat loads
High current density is involved
Long-term reliability matters more than price

Many of our customers reduce total project cost by switching to aluminum PCBs without sacrificing performance—once we review their thermal simulation data.

Where to Use Each PCB Type?

Here’s a quick-reference table to match your application with the recommended base material:

Application	Recommended Base	Reason
High-power LED floodlights	Copper	Heat and current requirements are high
Automotive lighting systems	Copper or thick aluminum	Performance and safety critical
Indoor LED lighting	Aluminum	Lower heat, cost-sensitive
Power modules & inverters	Copper	High voltage and thermal stress
Camera flash or ring light	Aluminum	Lightweight and cost-friendly
Medical power supply	Copper	Stability and safety required
LED floodlights (150W+)	Copper Core PCB	Handles heat better
LED bulbs & home lighting	Aluminum PCB	Affordable and thermally sufficient
EV chargers & power modules	Copper Core PCB	High reliability under load
Camera flashes & portable lights	Aluminum PCB	Lightweight and budget-friendly
Medical devices (power control)	Copper Core PCB	Precise, stable performance
Consumer electronics	Aluminum PCB	Cost-efficient for large volumes

Use this guide to avoid over-engineering or under-specifying your metal core PCB.

5 Key Points Before You Choose

Still not sure which base material fits your needs? Walk through this five-step checklist:

1. Power Level: How much current and heat does your circuit handle?

2. Installation Environment: Is weight a constraint? Will it face vibration?

3. Target Cost: Are you selling a premium or mass-market product?

4. Design Complexity: Do you need tight tolerances or complex routing?

5. Volume & Lead Time: Can your supplier meet deadlines for the material?

If you answered “high” for performance on most points, copper is likely the way to go. If not, aluminum is your best cost-performance choice. By the way, if you’re unsure after answering these, consult with your PCB manufacturer. At Best Technology, we provide application-based advice to help you choose between aluminum PCBs and copper core PCBs—without overspending.

Why Choose Best Technology for Your Metal Core PCB?

Whether you need aluminum base PCBs for standard lighting or copper base PCBs for high-power industrial applications, Best Technology has you covered:

Mature production lines for both copper and aluminum base PCBs
One-on-one design support, thermal simulation, and DFM reviews
Full in-house capabilities: thick copper etching, CNC routing, V-cutting
Fast sample turnaround and stable mass production support
Strict quality control and traceability through MES system
Expert engineering team for application-specific advice

Reach out to Best Technology—we’ll help you analyze your application, recommend the ideal PCB solution, and even support custom development if needed.

FAQs

Q1: Can I use aluminum base PCBs for high-power applications?

Only for moderate heat loads. For >100W power systems, copper is strongly recommended.

Q2: What is the thinnest aluminum or copper base you can provide?

We can produce down to 0.8mm base thickness for both, depending on the structure.

Q3: Do you offer hybrid metal core PCBs?

Yes, we can integrate aluminum and FR4 or support copper-ceramic hybrid designs.

Q4: How long is the lead time for copper vs aluminum base?

Aluminum PCBs: 5–7 working days; Copper PCBs: 7–12 days depending on complexity.

Q5: Can I get thermal simulation before placing an order?

Absolutely! We offer pre-production thermal analysis and structural design assistance.

Q6: Are copper core PCBs compatible with standard SMT processes?

Yes, they are. We offer full SMT assembly services for both aluminum and copper base boards.

Q7: How do I know which type is best for my application?

Send us your design or specs, and we’ll recommend the most cost-effective and reliable option.

Conclusion

Choosing between a copper core PCB and an aluminum PCB isn’t about choosing the better material. It’s about selecting what’s right for your application. Copper is powerful but expensive; aluminum is flexible and affordable.

When designed and selected correctly, aluminum PCBs can outperform expectations, and copper core PCBs can save your system from thermal failure. Match the material to your environment, budget, and performance goals—and you’ll never go wrong. In our next blog, we will share how to select the thickness of copper. If you are interested in it, collect us and keep reading.

Tags:copper base pcb, copper core pcb
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Custom PCB Sinkpad for High-power LED Solutions

Friday, May 23rd, 2025

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

What is a SinkPAD PCB and How Does it Work?

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

Custom PCB Sinkpad for High-power LED Solutions

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

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

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

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

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

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

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

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

What Materials are used in SinkPAD LED PCBs?

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

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

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

How is a SinkPAD PCB Manufactured?

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

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

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

Where are SinkPAD PCBs Used in Real Applications?

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

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

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

Design Considerations of SinkPAD PCB in LED Lighting Devices

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

1. LED Thermal Pad Alignment

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

2. Base Metal Selection

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

3. Board Thickness

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

4. Dielectric Isolation (If Applicable)

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

5. Surface Finish

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

6. Component Layout and Spacing

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

How Does Best Technology Serve You for Custom SinkPAD PCBs?

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

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

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

FAQs

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

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

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

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

3. Is copper better than aluminum for SinkPAD PCBs?

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

4. Are SinkPAD PCBs only used for LED lighting?

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

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

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

Tags:custom pcb sinkpad, sinkpad pcb
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How Does the Cost of Sinkpad MCPCB Compare to Conventional MCPCB?

Thursday, May 22nd, 2025

What Is Sinkpad MCPCB?

SinkPAD MCPCB is a special kind of metal core printed circuit board designed for excellent heat dissipation. It’s different from regular MCPCBs because it removes one major barrier—the insulating dielectric layer under the LED.

In simple terms, it allows heat to flow directly from the LED chip to the metal base. That means less heat build-up, more efficiency, and longer lifespan for your components.

You’ll often find SinkPAD MCPCBs in high-power LED applications—like automotive lighting, industrial lamps, medical equipment, and even UV curing systems. These are places where heat control isn’t just helpful—it’s essential.

Advantages of Sinkpad MCPCB

1. Direct Heat Flow

With no dielectric between the LED and metal core, SinkPAD boards offer a direct thermal path, reducing resistance and increasing efficiency.

2. Lower Operating Temperatures

By improving heat transfer, components stay cooler. For LEDs, this means stable brightness and a longer working life.

3. Consistent Light Output

Temperature spikes can dim or discolor LEDs. SinkPAD keeps the junction temperature stable, maintaining consistent color and brightness.

4. Compact Design

Thanks to better heat handling, you can reduce or eliminate bulky heatsinks, helping make designs smaller and lighter.

5. Durability in Harsh Conditions

SinkPAD boards resist thermal cycling, shock, and vibration, making them perfect for tough environments like aerospace or outdoor lighting.

So if your design involves powerful LEDs or components that get hot fast, this type of board can be a game-changer.

Base Materials of Sinkpad MCPCB

SinkPAD boards come with different base metals. Each one has its own strengths depending on your project.

Aluminum Core Sinkpad PCB

Aluminum is the more common choice. It’s lightweight, easy to work with, and keeps costs low. Its thermal conductivity is good—usually around 150-200 W/m·K. For applications where heat output isn’t extreme, aluminum SinkPAD PCBs are a great fit. You’ll find them in general LED lighting, backlit signs, and other consumer electronics.

They’re also a smart option if you’re trying to keep your SinkPAD MCPCB price in check. But actually, for consumer electronics, conventional metal core PCB can cover it.

Copper Core Sinkpad PCB

Copper is all about performance. It has much higher thermal conductivity—around 385-400 W/m·K—which means it can handle intense heat. If your LEDs are pushing a lot of power or operating in a hot environment, copper is the better option. Some industrial like UV lights, high-performance lasers, or automotive headlights that stay on for long hours.

Copper boards are heavier and more expensive than aluminum ones, but they deliver top-tier thermal results.

How Does Sinkpad MCPCB Work?

In a standard MCPCB, the LED sits on a copper trace. Under that trace is a dielectric layer. Below that is the metal core, its structure just like below. Heat has to travel through all of this to get out. That creates resistance.

However, sinkPAD skips the dielectric layer—at least under the LED’s thermal pad. Instead, the heat flows straight from the LED’s thermal pad into a thermal cavity that connects directly to the base metal. This structure is often called a Direct Thermal Path (DTP).

It’s like giving heat a shortcut out of the system. No extra layers. No slowdowns. Just fast, efficient cooling. This design improves overall thermal conductivity and gives you tighter control over junction temperatures.

Thermal Conductivity of Sinkpad MCPCB

Thermal conductivity is key when you’re dealing with LEDs and power electronics. The better the board can spread heat, the better your device performs.

With aluminum cores, you’ll typically see thermal conductivity in the 150–200 W/m·K range. That’s solid for most LED needs. With copper cores, you’ll reach up to 400 W/m·K, giving you elite heat handling.

Sinkpad MCPCB vs. Conventional MCPCB

So what are the differences between sinkpad metal core PCB and traditional metal core PCB? Here we made a comparison between them:

Property	SinkPAD MCPCB	Conventional MCPCB
Heat Transfer	Direct path (through convexity pad)	Through dielectric
Thermal conductivity	Up to 400W/m.k	Up to 8W/m.k
Thermal Resistance	0.4°C/W or lower	1.0–2.0°C/W
Light Stability	High (because most use copper)	Medium
LED Lifespan	Extended	Shorter under heat
Space Needed	No	Larger cooling required
Cost	Slightly higher	Lower upfront

SinkPAD boards give better performance and better results—especially when heat control is non-negotiable. They cost more, but what you get in return is worth it in critical applications.

Considerations When Using Sinkpad MCPCB

SinkPAD MCPCBs aren’t plug-and-play for every project. There are a few things you’ll want to keep in mind before designing with them.

1. Know Your Heat Load

If your LEDs don’t generate much heat, you might not need SinkPAD. But if your design involves high wattage, tight spaces, or long run times—then yes, it’s worth considering.

2. Choose the Right Core

Use aluminum if your budget is tight or if weight is a concern. Go with copper when you need every ounce of thermal performance you can get.

3. Plan for Heatsinks

Even though the board transfers heat well, it still needs a place to send that heat. Match your SinkPAD PCB with a proper heatsink or thermal interface.

4. Soldering Profiles

Because these boards transfer heat so quickly, your reflow or wave soldering profile might need to be adjusted. Too much heat too fast can be a problem.

5. Work With an Experienced Supplier

Not all board suppliers are familiar with SinkPAD technology. Make sure your manufacturer knows how to handle the convexity design and machining process correctly. If you are searching for a reliable sinkpad MCPCB manufacturer, do not miss out Best Technology. We have over 18 years experiences, and we have experienced engineers and operators to give you a high quality sinkpad copper core PCB.

How Does the Cost of Sinkpad MCPCB Compare to Conventional MCPCB?

So, how does the cost of sinkpad MCPCB compare to the conventional MCPCB? Actually, the price of sinkpad PCB is higher than that of a standard MCPCB. Because the process is more complex. There’s more precision involved in removing the dielectric under the LED. And if you’re using copper, that adds more to the cost.

Here’s what influences the price:

Core material (aluminum vs. copper)
Board size and thickness
Layer count
Volume of your order
Custom thermal pad design

But here’s the real question: does it save you money in the long run? For many, the answer is yes. Here’s why:

You don’t need oversized heatsinks
Your LEDs last longer
Fewer failures mean lower service costs
Your product performs better, with fewer returns

When you weigh the total system cost—not just the board—the extra investment often pays off.

SinkPAD MCPCBs offer a smart solution for thermal challenges in LED and power electronics. They bring something special to the table—direct heat transfer from the source to the metal base.

If your design involves strong heat loads, tight spaces, or critical reliability, this is the kind of PCB that can make a difference. In our next blog, we will share the factors affect the cost of sinkpad PCB. If you want to know more about sinkpad PCB, you are welcome to contact us at any time.

FAQs

1. What makes Sinkpad MCPCB more effective than a standard MCPCB?

It creates a direct path from the LED to the metal core, removing the thermal barrier and increasing heat flow.

2. Can I use aluminum Sinkpad MCPCB for high-power LEDs?

Yes, if thermal output is moderate. For extreme power or heat, copper may perform better.

3. Does it support double-layer designs?

Sinkpad technology is usually single-sided due to its thermal cavity, but custom options are available.

4. Is the cost justified in consumer products?

In mid- to high-end products where longevity and brightness matter, yes. It reduces long-term failures and service needs.

5. How do I choose between aluminum and copper Sinkpad cores?

Look at the application. If weight and cost are more critical, aluminum works well. For demanding environments, copper is better.

Tags:sinkpad mcpcb, sinkpad mcpcb price
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5 Factors Affect the Price of Sinkpad PCB

Tuesday, May 20th, 2025

What is Sinkpad Copper Based PCB?

A sinkpad copper based PCB, also known as SinkPAD board or thermoelectric copper separation copper based PCB, is a specialized type of metal core printed circuit board. It mainly consists of two major parts: the top trace layer and the copper core/substrate. The top trace layer contains the electrical traces for the circuit, while the copper core serves as a heatsink.

A 1 – Layer SinkPAD board, a common type, consists of a copper circuit layer, a dielectric (non – conducting) layer, and a metal core/pedestal which is usually copper. It belongs to single – sided SinkPAD PCB and DTP (Direct Thermal Path) board, and is the most popular and cost – effective stack – up option with the fastest lead time.

Sinkpad Copper Based PCB: Everything You Need to Know

Why Use Sinkpad Copper Based PCB?

Sinkpad copper based PCBs are used for several important reasons. After lamination, the electronics connection is on the trace layer, and the direct thermal conducting PAD comes from the copper core. The trace PAD on the trace layer is in the sink area of the copper core, which gives it the name “SinkPAD board”. This design allows for efficient thermoelectric separation.

These PCBs can reach a thermal conductivity of 400W/m.K. This high thermal conductivity is crucial in applications where heat dissipation is a major concern, such as in high – power LED lighting, power electronics, and other electronic devices that generate a significant amount of heat. By effectively dissipating heat, sinkpad copper based PCBs can improve the performance and reliability of electronic components and extend their lifespan.

Factors Affect the Price of Sinkpad MCPCB

Material type (aluminum vs. copper)

The choice of material has a significant impact on the price of sinkpad MCPCB. Copper is generally more expensive than aluminum. Copper has excellent thermal conductivity, which is one of the key advantages for sinkpad PCBs as it helps in better heat dissipation. However, the higher cost of copper raw materials and the more complex processing requirements contribute to the increased price.

Aluminum, on the other hand, is a more cost – effective option. It has relatively good thermal conductivity and is lighter in weight. But its thermal performance is not as good as copper. When the application requires high – end thermal performance, copper is often the preferred choice, but it comes at a higher price.

Board size and thickness

The size and thickness of the sinkpad copper based PCB also play a role in determining the price. Larger boards require more raw materials, such as copper and dielectric materials. Additionally, the manufacturing process for larger boards may be more complex, as it requires more precise alignment and processing steps.

Thicker boards also add to the cost. Thicker copper cores or additional layers of materials increase the material cost. Moreover, thicker boards may require more advanced manufacturing techniques to ensure proper electrical and thermal performance, which can drive up the production cost.

Layer structure

The layer structure of the sinkpad PCB is another important factor. A more complex layer structure, such as multi – layer sinkpad PCBs, is more expensive than single – layer ones. Multi – layer PCBs require more manufacturing steps, including additional lamination processes, drilling for vias to connect different layers, and more precise alignment of the layers.

Each additional layer adds to the complexity and cost of the manufacturing process. For example, a 1 – Layer SinkPAD board is the simplest and most cost – effective option, while a PCB with multiple trace layers and copper core layers will be significantly more expensive.

Order quantity

Order quantity has a direct impact on the price of sinkpad copper based PCBs. When the order quantity is large, the per – unit cost usually decreases. This is because manufacturers can take advantage of economies of scale. They can purchase raw materials in bulk at a lower cost, optimize their production processes, and reduce setup costs per unit.

For small – quantity orders, the fixed costs associated with setting up the production line, such as tooling costs and programming costs, are spread over a smaller number of units. As a result, the per – unit price is higher. So, customers who need a large number of sinkpad PCBs can often negotiate a better price per unit.

Custom thermal pad design

Custom thermal pad designs can also increase the price of sinkpad copper based PCBs. Standard thermal pad designs are more cost – effective because they can be produced using existing manufacturing processes and tools. However, if a customer requires a custom thermal pad design, it may involve additional engineering work, such as designing new masks, adjusting the manufacturing process, and conducting additional testing.

Custom designs may also require special materials or manufacturing techniques to meet the specific thermal requirements. All these additional steps and requirements add to the overall cost of the PCB.

Sinkpad Copper Based PCB Applications

Sinkpad copper based PCBs have several common uses in the electronics industry:

Thermoelectric separation applications:

Since the trace layer of SinkPAD boards is usually on the top side, they belong to single – sided SinkPAD PCBs and Direct Thermal Path (DTP) boards. This makes them suitable for applications where thermoelectric separation is required. For example, the SinkPad board provides excellent heat transfer from the LED to the base metal (copper) plate while maintaining excellent electrical isolation.

High – power LED applications:

1 – Layer copper base SinkPad PCB: It can be used with surface mount and chip & wire components. The thermal PAD of the LED touches the convexity of the copper core/pedestal directly, achieving a thermal conductivity of 400W/m.K. The pad of the LED touches the copper base directly, allowing the heat generated by the LED to be dissipated quickly into the air or a heatsink, achieving the best heat dissipation and conduction.

2 – Layers copper base SinkPad PCB: It can also be used with surface mount and chip & wire components. Similar to the 1 – layer version, the thermal PAD of the LED touches the convexity of the copper core/pedestal directly, with a thermal conductivity of 400W/m.K.

In general, sinkpad copper based PCBs are used to provide superior thermal performance for medium – to high – power LEDs and other chips/components.

How Does A SinkPAD board Differ From A Traditional PCB?

A SinkPAD board is a special type of metal core PCB. In a SinkPAD board, the thermal conductive PAD is the convexity area of the copper core/pedestal, allowing the thermal PAD of the LED to touch the convexity area of the metal core directly. This enables the heat of the LED to be dissipated into the air much faster and more efficiently than a conventional PCB.

The SinkPad provides excellent heat transfer from the LED to the metal base plate/pedestal while maintaining excellent electrical isolation. The base copper base gives the board substrate mechanical integrity, distributes and transfers the heat to a heat sink, mounting surface, or directly to the ambient air.

In contrast, traditional PCBs do not have this direct thermal path feature. The heating of the LED in a SinkPAD board conducts directly into the copper core, which is different from the traditional thermal path. Due to this, a SinkPAD board can offer superior thermal performance for medium – to high – power LEDs or other chips/components.

How to Design a SinkPAD Board?

When designing a SinkPAD board, the following points need attention:

1. Panel layout design

If the board outline is not square or rectangle, the outline has to be made via CNC routing or Die – punching. While designing the panel layout, at least 2mm space between the edge of the SinkPAD board (SinkPAD PCB) should be kept in order for routing or Die – punching.

2. Routing and punching

Several layers of SinkPAD PCB will be routed together to save time. But for punching, there is only one layer of SinkPAD board (SinkPAD PCB) each time. Die – punching will be used only when there are big volume orders as the cost of die – punching tooling is higher compared with other ways.

Moreover, in the lamination process (laminate & align board before hot process lamination), after specific steps, the electronics connection will be on the trace layer and the direct thermal conducting PAD comes from the copper core. The trace PAD on the trace layer seems in the sink area of the copper core, which is how the SinkPAD board gets its name. And because the electronic – related function is on the trace layer and thermal conduction is on the copper core, they are separated from each other, so it is also named a Thermoelectric separation circuit board.

Your Trust Sinkpad PCB Supplier – Best Technology

Best Technology is a reliable supplier of sinkpad PCBs. We offer high – quality SinkPAD boards with excellent thermal performance. Our products are designed and manufactured using advanced techniques to ensure precise separation of the copper core and trace layers, resulting in efficient thermoelectric separation.

Best Technology can provide various types of sinkpad PCBs, including 1 Layer SinkPAD boards, 2 layers sinkpad MCPCB and multi-layer sinkpad MCPCB, to meet different customer requirements. We also have the ability to handle custom designs, whether it’s a custom thermal pad design or a specific layer structure. With their expertise and experience in the field, customers can trust Best Technology to deliver high – quality sinkpad copper based PCBs at a reasonable price.

Frequently Asked Questions

1. What is a double – sided SinkPAD board?

A double – sided SinkPAD board consists of at least one layer of circuit layer on both the top and bottom sides of the SinkPAD board, a dielectric (non – conducting) layer, and a metal core/pedestal which is normally copper. More components can be placed on this type of board, but engineers need to consider heat conduction.

2. What are the components of a 1 – layer SinkPAD board?

A 1 – layer SinkPAD board consists of a copper circuit layer, a dielectric (non – conducting) layer, and a metal core/pedestal which is usually copper. It belongs to single – sided SinkPAD PCB and DTP board and is the most popular and cost – effective option with the fastest lead time.

3. How is a 2 – layer SinkPAD board different from a 1 – layer one?

A 2 – layer SinkPAD board has two layers of circuit layer on the same side, along with a dielectric layer and a copper metal core/pedestal. It also belongs to single – sided SinkPAD PCB and DTP board. The main difference is that more traces can be placed on a 2 – layer SinkPAD board compared to a 1 – layer one.

4. What defines a multi – layer SinkPAD board?

Multi – layer SinkPAD refers to a metal core board that has more than 2 layers of trace circuits, either on the same side or on both the top and bottom sides, and has a direct thermal path (PAD). Examples include 4L SinkPAD board or 4L SinkPAD double – sided board.

5. What is the first step in the SinkPAD board manufacturing process?

The first step in the SinkPAD board manufacturing process is to prepare the manufacturing files. This involves separating the copper core and trace from one Gerber layer into two different layers. One layer will have only the trace without the center heatsink PAD of the LED (trace layer), and the other layer will have only the heatsink PAD (copper core layer).

Tags:MCPCB, sinkpad copper based pcb, sinkpad pcb
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