Archive for the ‘SinkPAD’ Category

Copper Metal Core PCB, Copper Core PCB Factories & Manufacturer

星期四, 24 4 月, 2025

Copper Core Metal Core PCB Definition

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

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

Copper Metal Core PCB, Copper Core PCB Factories & Manufacturer

Copper Core PCB Structure

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

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

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

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

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

Types of Copper Core PCB

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

Normal Copper Core PCB

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

SinkPad Copper-Based PCB

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

Sinkpad copper-based pcb stack up:

Features of Copper Core PCB

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

Copper Metal Core PCB Design Guidelines

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

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

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

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

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

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

Copper Metal Core PCB Applications

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

How to Choose Copper Core PCB Factories?

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

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

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

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

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

1. Adwin Circuits

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

2. PCBgogo

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

3. Millennium Circuits Limited (MCL)

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

4. Best Technology

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

5. PCBWay

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

6. Sierra Circuits

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

7. JLCPCB

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

8. FX PCB

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

9. PCBONLINE

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

10. Leiton GmbH

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

Why Choose Best Technology as Your Copper Core PCB Supplier?

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

Copper Metal Core PCB Prototype

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

Copper Metal Core PCB Assembly

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

FAQs

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

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

2. Can copper core PCBs support multilayer designs?

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

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

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

4. Are copper metal core PCBs expensive?

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

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

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

Our Core Services – From Design to Assembly

We provide a wide range of services to support your project at every stage:

PCB Design & DFM Check – We don’t just manufacture—we help you build better boards. Send us your layout or concept, and our senior engineers will review your files for manufacturability, improving your design before it hits the production line.
PCB Fabrication – Single-layer, multi-layer, HDI, aluminum-based, or ceramic—we fabricate PCBs of all complexities. Our in-house plant supports quick turnarounds and strict quality control for every batch.
PCB Prototype – Need your prototype in 24–72 hours? We’ve got your back. Ideal for engineers in the development phase, we offer fast PCB prototyping with full traceability, fly-probe testing, and surface finish options.
PCB Assembly – Our turnkey PCB assembly service covers everything from component sourcing, SMT/DIP soldering, to functional testing. You send us your BOM and Gerber—we handle the rest.
Components Sourcing – Reliable sourcing of original, competitive prices, traceable electronic components.
IC Programming – Pre-programming and testing of integrated circuits to streamline your assembly process.

What PCB Types Does Best Technology Manufactured?

We are capable of manufacturing a wide variety of PCB types, including but not limited to:

FR4 PCBs (high speed PCB, IC substrate, high TG PCB, extra thin PCB, our special semi-rigid flex PCB and so on.)
Metal Core MCPCBs (aluminum based PCB, copper clad PCB, sinkpad PCB, thermoelectric copper separate PCB)
Ceramic PCBs (AlN, BeO, Al₂O₃, Zro2)
Flexible and Rigid-Flex PCBs, FFC, Dual access PCB
HDI PCBs
High-Frequency PCBs
Heavy Copper PCBs
Busbar PCBs
Hybrid Substrate PCBs

PCB Fabrication Manufacturer, Prototype, Design and Assembly

Whether you need high-reliability boards for aerospace, thermally conductive boards for LEDs, or RF boards for communication devices, we have the capability to deliver.

PCB Prototype Lead Time

We understand how crucial speed is in product development. Our standard PCB prototype lead time is:

Single-layer & double-layer PCBs: as fast as 24 hours
4-layer PCBs: typically 48–72 hours
6-layer or above: around 3–5 working days, depending on complexity

Below is a detailed prototype lead time sheet at Best Technology, the expedited options are available to meet urgent project deadlines.

Prototype(<1m²)	Layers	Normal Service	Expedited Service
FR4 PCB	1 Layer	3-4 days	24 hours
	2 Layers	4-6 days	24 hours
	4 Layers	8-10 days	48 hours
	6 Layers	8-10 days	72 hours
	8 Layers	10~14 days	72-96 hours
	10 Layers	14-18 days	72-96 hours
	HDI (1+N+1 2+N+2)	2.5 – 3.5weeks	TBD (depend on design)

Best Technology’s PCB Assembly Capabilities

And as a one-stop service provider to customers, we offer PCB assembly service as well, such as:

SMT (Surface-Mount Technology)
DIP (Dual In-line Package)
Reflow Soldering (for SMD components)
Wave Soldering (for DIP components)
Hand Soldering (connectors, through hole components)
Mixed Assembly Technologies
Wire Harness Assembly
PCBA Testing
Box Building Assembly

How to Work with us – From File to Finished Board?

Step 1: Upload Your Files

Submit your Gerber, BOM, or PCB design files via our secure portal. We support various formats and guarantee file confidentiality.

Step 2: Engineering Review & Instant Quote

Our team performs a DFM check and confirms design compatibility. You’ll receive a quote and estimated lead time within 2 hours.

Step 3: PCB Fabrication & Parts Procurement

We begin board production and source parts simultaneously through authorized channels like Mouser, DigiKey, and Arrow.

Step 4: SMT/DIP Assembly & Testing

Boards are assembled in our SMT lines with 3D AOI, X-ray, and functional testing to ensure performance and soldering quality.

Step 5: Secure Packaging & Global Shipping

We pack your PCBs using anti-static materials and ship via DHL, FedEx, or your chosen method. Worldwide delivery in 3–5 days.

Custom PCB Board Quote

Not sure about all your PCB specs? No problem — we’re here to help.

Request a custom PCB board quotation if your project includes any of the following advanced requirements:

Controlled Impedance
Via Filling or Plugging
Blind or Buried Vias
Heavy Copper (≥ 2oz)
Controlled Dielectric Thickness
Edge Plating
CPK Requirements

Simply share what you do know — our engineering team will review your files and guide you through the rest.

FAQs

Q1: What file formats do you support?

Gerber (RS-274X), BOM (Excel), Centroid files, Pick & Place, Altium, Eagle, and PDF for reference.

Q2: Can I order just a few prototype boards?

Yes, our minimum order starts from 1 piece for PCB prototypes.

Q3: Do you provide components?

Yes! We offer full turnkey assembly, including sourcing components from trusted suppliers.

Q4: How do you ensure quality?

Every board is electrically tested (flying probe/fixture), and assembly passes AOI and functional testing before shipment.

Q5: Do you offer NDA for file protection?

Absolutely. We provide NDA upon request and all files are kept confidential.

What is Direct Thermal Path MCPCB?

A Direct Thermal Path MCPCB (DTP MCPCB) also called sink Pad MCPCB, or thermoelectric separation MCPCB. It is a specialized type of metal-core PCB that design with a thermal convexity Pad to create a direct thermal path. It made of copper core/pedestal, so that the thermal Pad of LED chips can touch the convexity area of metal core directly, ensure a better heat dissipation.

The core of these boards is typically made of copper for ultra-high conductivity. The magic happens in the convexity Pad —a thin, thermally conductive that bonds the circuit layer to the metal base directly. See the stack up of a direct thermal path PCB as below for make sense:

Why Does Direct Thermal Path PCB Matter?

Heat is the enemy of electronics. When components overheat, performance drops, lifespans shorten, and failure risks rise. For example, an LED’s brightness can fade by 30% if its temperature rises just 20°C above optimal levels. Direct Thermal Path MCPCBs solve this by:

Cutting thermal resistance: Heat escapes 8–10x faster than in standard boards.
Preventing hotspots: Even temperature distribution avoids component burnout.
Improving reliability: Cooler parts = 50% fewer breakdowns in harsh environments.

For industries where reliability is non-negotiable—like aerospace or medical devices—this tech is a game-changer. A drone’s flight controller using DTP MCPCBs, for instance, can handle prolonged use without throttling performance.

Benefits of Direct Thermal Path MCPCB

Superior Heat Management: Direct contact with the metal core allows faster heat transfer, 8–10x faster than standard FR4 PCBs.
Higher Component Reliability: Stable temperatures reduce stress on electronic parts.
Compact Designs: No bulky heatsinks needed—ideal for slim devices like VR headsets.
Longer Lifespan: Heat-sensitive components last longer due to better thermal management.
Cost-Effective: Fewer cooling parts mounted, reducing 15-20% assembly costs.
Versatility: Works in extreme temps (-50°C to 300°C).
Increased Energy Efficiency: Lower thermal resistance enhances overall power efficiency.
Consistent Performance – Devices run more reliably under high-power conditions.

Direct Thermal Path MCPCB Key Components

The materials used in DTP MCPCBs play a significant role in performance. Common options include:

1. Metal Core (Base Layer)

The metal core provides structural integrity and acts as the primary heat dissipator. Options include:

Copper – Mostly used. Superior thermal performance (up to 400 W/m·K) but heavier and more expensive.
Aluminum – Lightweight, but it is rarely made, because normal aluminum PCB can meet most of heat dissipation needs.

2. Circuit Layer (Copper Foil)

1oz to 6oz copper thickness depending on the application. Thicker copper enhances current-carrying capacity and heat dissipation.

3. Dielectric Layer (Optional in Some Designs)

In regular MCPCBs, this layer insulates the circuit from the metal core.
In DTP MCPCBs, selected areas have no dielectric layer, ensuring direct heat transfer.

4. Solder Mask & Silkscreen & Surface Finish

Solder Mask – Protects the copper circuit from oxidation and damage.
Silkscreen – Printing labels, company logo, trace names etc for identifying and smooth PCB assembly process.
Surface Finishes – Options like ENIG, OSP, or HASL prevent corrosion and enhance solderability.

Types of Direct Thermal Path MCPCB

Single-Layer DTP:

Basic design with one conductive layer.

Ideal for simple LED lighting (e.g., household bulbs).

Cost-effective for high-volume production.

Double-Layer DTP:

Extra layer for complex circuits.

Used in automotive controls (e.g., EV battery monitors).

Supports moderate power loads (50–100W).

Multi-Layer DTP:

Advanced setups with 4+ layers for high-density electronics.

Common in servers, 5G infrastructure, and industrial robots.

Handles 200W+ components with ease.

For more information of each type and direct thermal path MCPCB stack up, click into our official website:

DTP MCPCB vs. Regular MCPCB

The thermal conductivity of the thermoelectric separation MCPCB is as high as 380W/m.K, which is much higher than the 1-2W/m.K‌ of the regular metal core PCB. The thermoelectric separation structure makes the LED chip directly touch with copper substrate, reducing the thermal resistance, thus improving the heat dissipation effect. In addition to this, the fabrication process of DTP MCPCB is more complex‌, manufacturers need to purchase copper base and insulation layer, then processing and laminating separately. Here are some other differences between the two:

Feature	DTP MCPCB	Regular MCPCB
Thermal Resistance	Lower due to direct heat path	Higher due to dielectric layer
Heat Dissipation	Faster and more efficient	Slower, limited by dielectric layer
Weight	Slightly heavier due to copper core	Lighter in some cases (when used aluminum as core)
Thermal Path	Direct (no gaps)	Insulated (slower transfer)
Applications	EVs, industrial lasers	Consumer electronics, low-power

Applications of Direct Thermal Path MCPCB

DTP MCPCBs are widely used in industries requiring high-performance thermal solutions:

LED Lighting – Enhances efficiency and longevity in high-brightness LED modules.

Power Electronics – Used in inverters, power supplies, and energy storage systems.

Telecommunication – Improves stability in high-frequency and RF applications.

Medical Devices – Ensures reliability in imaging systems and diagnostic tools.

Automotive Industry – Supports high-power applications like EV battery management.

Aerospace & Defense – Used in radar systems and avionics for thermal stability.

Manufacturing Process of Direct Thermal Path MCPCB

1. Preparation of Manufacturing Files

The first step is preparing the manufacturing files. This involves separating the copper core and circuit traces from a single Gerber layer into two distinct layers. The trace layer contains only the circuit traces without the central heatsink pad of the LED, while the copper core layer consists solely of the heatsink pad. This separation ensures precise processing in later stages.

2. Production of the Trace Layer and Copper Core Layer

Both layers are produced separately.

Trace Layer Production

The trace layer follows a standard PCB manufacturing process, using materials like FR4 or BT (Bismaleimide-Triazine), with BT being the preferred choice due to its thermal properties.

Copper Core Layer Processing

Processing the copper core is more complex.

a) The copper core thickness typically ranges from 0.8mm to 2.0mm and comes with protective blue film on both sides. The film is removed before etching to expose the copper surface.

b) After the raw material is cut, the copper core undergoes grinding to remove impurities, ensuring a clean surface for the next steps.

c) A blue film layer is applied over the entire copper core. After the developing and etching process, only selected areas of the blue film remain, marking the locations of the heatsink pad.

3. Lamination of the Trace Layer and Copper Core Layer

Once both layers are prepared, they are laminated together.

Glue is applied to the bottom side of the trace layer for bonding.
CNC milling/routing is performed to remove the cutout areas where the raised heatsink pad will be placed.
After peeling off the white release paper, the trace layer is aligned and placed onto the copper core, forming the SinkPAD structure that enhances thermal performance.

4. Solder Mask Application

After hot lamination, the boards are cleaned before applying the solder mask.

A stencil is used to align the board before printing solder mask ink.
The solder mask color is applied using either a manual process for small batches or an automatic printer for mass production. Common colors include white, black, green, blue, yellow, and red.
The boards are left to stand for one hour before being baked in an oven.
The solder mask is then developed using UV light exposure and etched, leaving only the required solder mask areas.

5. Silkscreen Printing

Silkscreen markings are printed using a silk-screening process without requiring additional development or etching. This step ensures component labels and markings are clearly visible.

6. Surface Finishing

A suitable surface treatment is applied to the exposed copper areas to improve solderability and prevent oxidation.

Common finishes include OSP (Organic Solderability Preservative) and ENIG (Electroless Nickel Immersion Gold).
HAL (Hot Air Leveling) is not used for SinkPAD boards due to process limitations.
Special surface finishes can be applied based on customer requirements.

7. Final Inspection and Shipment

Each board undergoes a strict electrical test (E-testing) and final quality control (FQC) to verify circuit integrity and manufacturing accuracy. Once approved, the boards are carefully packed and shipped according to customer specifications.

Throughout the entire process, every step is closely monitored to ensure high-quality solder masks, precise silkscreen printing, and flawless surface finishing, meeting all design and performance expectations.

Why Choose Best Technology?

With over 18 years of experience, Best Technology is a trusted name in PCB manufacturing. Our DTP MCPCBs deliver superior thermal management, longer lifespan, and excellent performance. Whether you need high-power LED PCBs, automotive PCBs, or industrial thermal solutions, we provide tailored solutions to meet your needs.

Our Direct Thermal Path MCPCB Manufacturing Capability

Best Technology specializes in custom DTP MCPCBs with the following capabilities:

Base material: Copper core: 0.8mm, 1.0mm, 1.2mm, 1.4mm, 1.5mm

Thermal Conductivity: 400 W/m.K.

Board Thickness: 1.0 mm~2.0mm(0.04″~0.08″)

Copper thickness: 0.5 OZ, 1.0 OZ, 2OZ, (specially 3-10 OZ)

Outline: Routing, punching, V-Cut

Soldermask: White/Black/Blue/Green/Red Oil

Legend/Silkscreen Color: Black/White/Yellow

Surface finishing: Immersion Gold, ENEPIG, Immersion Tin, OSP

Max Panel size: 600*500mm(23.62″*19.68″)

Packing: Vacuum/Plastic bag

Samples L/T: 1.5~2.5 weeks

MP L/T: 2.5~3.5 weeks

For premium Direct Thermal Path MCPCBs, contact Best Technology today!

What is Metal Core Printed Circuit Board?

A metal core printed circuit board (MCPCB) is a type of PCB that incorporates a metal core, usually aluminum or copper, as its base material. This core helps to enhance the board’s thermal management capabilities. Unlike traditional PCBs made of fiberglass (FR4), MCPCBs are designed to dissipate heat more effectively, making them ideal for applications where heat dissipation is crucial.

MCPCBs are also referred to as insulated metallic substrate (IMS), or insulated metal PCBs (IMPCB), thermal-clad PCBs. A typical metal core PCB is made of thermal insulating layer (dielectric layer), metal base and copper foil.

The basic constructure of a metal core circuit board includes:

Silkscreen
Solder mask (S/M)
Circuit layer (copper foil layer)
Dielectric layer
Metal core base

What are Metal Core PCBs Used For?

Metal core PCBs are popular because of its good thermal management. It utilizes in various applications that demand efficient heat dissipation and high thermal performance. Here are some common applications that metal core printed circuit board will be used in.

LED lighting

MCPCBs are widely used in LED lighting systems due to their excellent thermal management properties. LEDs generate a significant amount of heat, and metal core PCBs help to dissipate this heat effectively, ensuring longer lifespan and consistent performance of the LEDs.

Power supplies

High-power supply units benefit from MCPCBs as they can handle the heat generated by power components. This helps in maintaining the stability and efficiency of the power supply over time.

Automotive electronics

In the automotive industry, MCPCBs are used in various electronic control units (ECUs), lighting systems, and other high-power applications. The robust nature of MCPCBs makes them suitable for the harsh conditions experienced in automotive environments.

Industrial equipment

Industrial machinery and equipment that operate under high temperatures or require high power output use MCPCBs for their thermal management capabilities. This ensures the reliability and longevity of the equipment.

Telecommunications

Telecommunications equipment, such as base stations and routers, use MCPCBs to manage the heat generated by high-speed and high-frequency operations, ensuring uninterrupted performance and reliability.

Consumer electronics

High-performance consumer electronics, including laptops, smartphones, and gaming consoles. They install with MCPCBs to manage heat and improve device performance and lifespan.

What are the Advantages of Metal Core PCB?

Metal core PCBs are preferred for several reasons, primarily revolving around their superior heat dissipation capabilities and mechanical strength. Here are some main advantages of metal core PCBs.

Superior thermal management
Mechanical strength
Compact design
Enhanced performance
Improved reliability
Higher recyclability
Cost Efficiency
Dimension stability
Size reduction
Longer lifetime

What Metal is Used in PCBs?

The choice of metal in PCBs significantly affects their thermal and mechanical properties. The most commonly used metals in MCPCBs are aluminum and copper. Here’s a closer look at these materials:

Aluminum

Thermal Conductivity: Aluminum has a thermal conductivity of approximately 1.0 to 2.0 W/mK, making it an excellent material for heat dissipation.
Cost-Effective: Aluminum is relatively inexpensive compared to other metals, making it a cost-effective choice for many applications.
Lightweight: Aluminum is lighter than copper, which can be beneficial in applications where weight is a concern.
Corrosion Resistance: Aluminum naturally forms a protective oxide layer, enhancing its resistance to corrosion.

Copper

Thermal Conductivity: Copper has a higher thermal conductivity than aluminum, ranging from 3.0 to 5.0 W/mK, providing superior heat dissipation.
Electrical Conductivity: Copper is also an excellent conductor of electricity, which can improve the electrical performance of the PCB.
Durability: Copper is more durable and resistant to wear and tear compared to aluminum, making it suitable for more demanding applications.
Higher Cost: Copper is more expensive than aluminum, which can increase the cost of the PCB but is justified in applications requiring superior performance.

Other Metals

In some specialized applications, other metals like stainless steel or alloys might be used, but these are less common due to their specific properties and higher costs.

What is the difference between FR4 PCB and Aluminum PCB?

Aluminum PCB is a material based on aluminum base material, coated with an insulating layer and other conductive layers on the aluminum base material. FR4 is a glass fiber reinforced laminate, made of multi-layer fiber cloth and resin composite. In the following, we will introduce the difference between aluminum substrate and FR4 in terms of thermal conductivity, mechanical strength, manufacturing difficulty, application range and thermal expansion coefficient.

1. Aluminum substrate has good heat dissipation, and its thermal conductivity is about 10 times that of FR4.

2. The mechanical strength and toughness of the aluminum substrate are better than FR4, which is suitable for installing large components and making large-area pcb boards.

3. The production of aluminum substrate requires more process steps, and its production process is more complex than FR4, and the production cost is higher than FR4.

4. The aluminum substrate is suitable for high-power electronic products such as LED lighting, power supplies, inverters and solar inverters, and FR4 is suitable for low-power electronic products such as televisions, telephones and electronic game consoles.

5. The thermal expansion coefficient of aluminum substrate is close to that of copper foil, which is smaller than that of FR4, which is good for ensuring the quality and reliability of the circuit board.

https://www.youtube.com/watch?v=KFQNdAvZGEA&list=PLh7eQ1tIPsW456K51PERNxBMK0r9lRg1e

How to Design Metal Core PCB?

Designing a metal core PCB is a complex process that includes several crucial steps. During the design, we should ensure the board meets the thermal, electrical, and mechanical requirements of the application. Below is a detailed guide to the MCPCB design process.

1. Define the Application Requirements

Before starting the design process, it’s essential to clearly define the requirements of your application. This includes understanding the thermal, electrical, and mechanical needs of the project. Determine the maximum operating temperature and the amount of heat that needs to be dissipated, ensuring the MCPCB can handle the thermal load effectively. Specify the electrical characteristics such as current load, voltage levels, and signal integrity requirements to ensure the board can deliver the necessary performance.

2. Select the Core Material

As mentioned above, there are two common metal materials used in this industry: aluminum alloy and copper core. They have unique characteristics and properties when used in device. So. choosing the appropriate metal core material is crucial for the performance of your electronic device. This table provides a side-by-side comparison of aluminum alloy and copper core materials, helping to choose the appropriate material when designing MCPCBs.

Property	Aluminum	Copper
Thermal Conductivity	1.0 – 2.0 W/mK	3.0 – 5.0 W/mK
Electrical Conductivity	Lower than Copper	High
Weight	Light	Heavy
Cost	Lower	High
Mechanical Strength	Good	Excellent
Corrosion Resistance	Natural Protective Oxide Layer	Requires Additional Protection
Thermal Expansion Coefficient	Higher	Lower
Machinability	Good	More Difficult
Environmental Impact	Recyclable	Recyclable
Application Areas	LED Lighting, Consumer Electronics, High-Performance	Electronics, Industrial Equipment

3. Determine the Layer Stack-Up

The layer stack-up defines the arrangement of the different layers in the PCB. A typical MCPCB stack-up includes:

Top Copper Layer: The conductive layer where components are mounted.
Dielectric Layer: An insulating layer that separates the copper layer from the metal core. It has good thermal conductivity to transfer heat from the components to the metal core.
Metal Core: The central layer made of aluminum or copper, which acts as a heat spreader.
Bottom Copper Layer (optional): Used in double-sided MCPCBs for additional routing of traces.

4. Design the Circuit Layout

The circuit layout includes placing components and routing traces on the PCB. Key considerations include strategically placing heat-generating components to ensure efficient heat dissipation and keeping sensitive components away from high-heat areas. Trace routing should minimize electrical interference and maintain signal integrity, using wider traces for high-current paths to reduce resistance and heat generation. Implementing thermal vias enhances heat transfer from the top copper layer to the metal core by using plated through holes that connect the copper layer to the metal core, facilitating better heat dissipation.

5. Design for Manufacturability (DFM)

Ensuring that your design can be efficiently manufactured is critical. Maintain adequate clearances between traces, pads, and other features to meet MCPCB manufacturing capabilities and avoid short circuits. Use standard drill sizes to reduce manufacturing complexity and cost. Apply a solder mask to prevent solder bridges and protect the copper traces from oxidation. Use clear and legible silkscreen markings for component identification and assembly instructions. You can communicate with your supplier and ask for a capability chart, so that can save much time on design phase.

6. Prototype and Test

Once the design is validated, create a prototype of the MCPCB and conduct thorough testing. Measure the actual thermal performance under operational conditions to verify the simulation results. Test the functionality of the PCB in the intended application environment to ensure it meets all performance requirements. Conduct reliability tests such as thermal cycling, vibration testing, and humidity testing to assess the durability of the MCPCB.

Best Technology – A Leading MCPCB Manufacturer in Asia

With 18+ years of experience in the PCB industry, Best Technology has a deep understanding of the complexities involved in MCPCB production. Our team of experts is adept at designing and manufacturing MCPCBs that deliver optimal performance. Best Technology offers customized turn-key solutions tailored to the specific needs of our clients. Whether it’s a unique design requirement or a specific material preference, we provide flexible options to meet diverse demands.

Contact Best Technology, get your quote right now to make your own metal core circuit boards!

What is thermal conductivity?

Thermal conductivity is a physical value signifies the capacity of a material to allow heat flow per unit area through it in a unit of time. A higher thermal conductivity indicates better heat conduction for the material. In the field of heat generation and thermal management products, thermal conductivity is a crucial parameter as it relates to the product’s heat dissipation capability and stability. In the structure of aluminum, the thermal conductivity layer is always stand between the copper circuit layer and base material, so that the heat generated by product can be transfer quickly to outside.

Significance of Thermal Conductivity in Aluminum PCBs

Aluminum substrates are commonly used materials in heat dissipation and thermal management products. Their thermal conductivity is a vital element evaluated heat dissipation properties typically in W/m·K. It can be understood as the material’s heat transfer rate, i.e., the amount of heat conducted per unit time. Specifically, assuming the same amount of heat is conducted in aluminum substrates and other materials, the conduction rate of aluminum substrate will be faster over a certain period. This implies that aluminum substrates can transfer heat more quickly from the heat source to the external environment, achieving efficient heat dissipation.

Impact of Thermal Conductivity on Heat Dissipation Products

The primary function of thermal management products is to dissipate heat. How does thermal conductivity specifically affect them? Let us dive into from below aspects:

1. Thermal Conductivity Value

A higher thermal conductivity leads to better heat dissipation capability, as it can achieve faster transfer of heat from the heat source to the environment. Therefore, thermal conductivity of aluminum substrates plays a crucial role in the heat dissipation products, such as the LED lights, industrial power devices, automotives. At Best Technology, the thermal conductivity we used for aluminum PCB always is range from 1.0 to 3.0W (thickness=75-200um). Different thermal conductivity value has its own thickness.

2. Product Stability

The stability of a product also depends on its thermal conductivity. According to our 17+ manufacturing experience, insufficient thermal conductivity in heat dissipation products may result in overheating during prolonged operation, potentially shortening the product’s lifespan. Let me take a simple example, assume your mobile phone is under long time playing games, then it will generate many heats, finally causing the overheating phenomenon. And this will shorten its lifecycle if you always do like that.

When it comes to thermal conductivity selection, there is a big misunderstanding is that some may believe that higher thermal conductivity in aluminum substrates is always better. However, this is not entirely accurate. While higher thermal conductivity is generally favorable, it does not mean that aluminum substrates with the highest thermal conductivity are suitable for all heat dissipation applications. In specific use cases, it is essential to choose the appropriate thermal conductivity for aluminum substrates based on actual requirements to achieve the optimal heat dissipation effect.

By the way, if you want to choose higher thermal conductivity value, ceramic PCB is a better choice, which can achieve 24W or more. It mainly depends on its ceramic substrate material, like the Al2O3 thermal conductivity value is around 24W~28W/m-K, while AlN enable to reach 150W~240W/m-K.

Conclusion

All in all, to ensure optimal heat dissipation effects and stability, it is crucial to choose the right thermal conductivity for aluminum substrates based on actual needs. The careful consideration of thermal conductivity values in aluminum PCBs is integral to the longevity and performance of heat dissipation products, emphasizing the importance of informed selection in the pursuit of effective thermal management.

Best Technology is an expert in metal core PCB manufacturing, we have strong R&D team and full-experienced employs that can provide with you the best metal core PCB solution. Welcome to contact us at sales@bestpcbs.com if you want to know more.

What affects the cost of a PCB?

Drives the cost of PCBs are numerous, we can see from the PCB itself, for example, circuit board substrate materials, the external factors such as the manufacturing difficulties, the whole order quantities and some other special requirements that from designers.

Here, we listing some basic parameter factors which drives the whole cost of a PCB.

PCB substrate material

The substrate of PCB board refers to the material used in the non-conductor part of the circuit board, mainly FR4, glass fiber, epoxy resin, polyimide, copper, aluminum and so on. In the PCB manufacturing, glass fiber is widely used in the manufacture of double-sided circuit board and multi-layer board, while epoxy resin and polyimide are used in the manufacture of high-density multi-layer board. Among them, copper substrate is most expensive material. No matter what kind of materials, all of them shall be calculated according to the real-time international price.

PCB size (panel and single pcs)

PCB size will determine the price of PCBs, this is for sure. Generally speaking, with a same number of PCB layers, the smaller the PCB size, the cheaper the cost. Because during calculating cost, vendors will consider the utilization rate of raw materials. Make sure the highest utilization, the cost for both purchaser and vender will be best. The raw material of PCBs is commonly 1200mm*1200mm, or 1220mm for special specifications, when the utilization achieves 90% or above, this is the best.

So, how to improve the utilization of raw materials? Normally, manufacturers will optimize the working files (WF) from single size to panel size, and then material will be cut according to the panel files. But if the panel size is not suitable, then there will be a lot of waste edges of raw material in the cutting process, and generally this will be added into your PCB price. So that the unit PCB price will be more expensive. In another word, if you PCB size is well-suited, then it is good for PCB manufacturer and yourself. And at this time, the utilization will be the highest and your PCB cost is the cheapest as well.

Line width/spacing

To a certain extent, as long as you are following the PCB design rules, the PCB price will not too high. However, if your design is complex and the line width is extreme thin, then the price will increase since it is difficult to control during manufacturing.

PCB layers

According to the IPC standard, PCBs can be classified to single-layer PCB, double sided PCB and multilayer PCB. For layer count over than 2 layers, we called it as Multilayer PCBs, such as 4 layers PCB, 6 layers PCB. For FR4 PCB, we can make up to 32layers.

Due to the manufacturing process and some unpredictable assembling cycles, the more the layers, the more expensive it is. (The price of single side PCB is the similar to double sided PCBs.)

Solder mask ink color

In the past, it is no doubt that you will spend more if you want every color expect green. But now things are changeable. Most colors are available at no or very little extra cost, which usually only occurs for unique requests such as matte tones.

PCB copper foil thickness

The weight of copper foil depends on the successful utilization of the material. Thicker copper is more expensive and comes with additional manufacturing difficulties and expenses. You may also have to fill the holes with copper foil to connect layers. In addition, heavier copper means you need to spend more cost in shipping. Let’s take a simple example, for aluminum core PCB and copper core PCB, in the same volume and quantities, copper core PCB stands out for expensive shipping cost since it has thicker copper and heavier weight.

PCB surface treatment

Surface treatment is a method that using for protecting the surface from corrosion and improve the solderability. Usually, in consideration of environmental friendliness, vendors can use a couple of gold or silver to achieve further safety for use in some applications.

The commonly used surface treatment methods include OSP, IMMERSION SILVER, ENIG, ENEPIG and HASL (LF). Among them, the price is ENEPIG>ENIG>IMMERSION SILVER>OSP>HASL. You can calculate the PCB board price according to the surface treatment method and gold thickness.

Quantity and lead time

When developing a new project, almost of companies would like to make prototypes first and ask for a sample quotation. However, some PCB manufacturers will set the minimum order quantity, the smaller the quantity, the higher cost the PCB board. Please make sure to check the price for different amount before placing an official order.

Meanwhile, the delivery time request also will affect the whole price in a certain. And certainly, the price of quick turn order and expedited service will higher than normal order.

Other special requirements (impedance, IPC standard)

To ensure the stable transmission of circuit board signals and improve the quality of signal transmission, designers and engineers will ask for impedance control for the traces. This can be seen as special requirements, so it will add a few extra prices. And the required IPC Criteria is a factor as well. Normally, if customer does not have other request, we will default use IPC class II. III level will more expensive.

Above all are the mainly factors that affect the price composition for a printed circuit board. When evaluating your PCB cost, making them in your consideration is best.

PCB and PCBA supplier that can save cost for you – Best Technology

When you are seeking for a reliable PCB and PCBA supplier, I would like to recommend Best Technology to you. Best Tech offers one-stop service including raw material purchasing, PCB making, components searching, assembly, box building and package out of warehouse. What we can provide is not limited to PCB, but also metal core PCB, ceramic PCB, flexible PCB, rigid flex PCB, special PCB like HDI PCB, heavy copper PCB, extra thin PCB and so on. During the 17 years, the Best Technology company has served include medical industry, consumer electronics, new energy, automotive electronics, aerospace, military and others.

Could it be said that you are searching for a PCB supplier that can provide favorable price that lower than market? If this is true, please go ahead and reach us today, let’s talk about more PCB information right now and start our business trip together. We promise, when you decide to take the first step, and we’ll take the remaining 99 steps.

What is Copper PCB?

Copper PCB, also known as Copper Core PCB, Copper-based PCB or Copper Clad PCB, which is a type of metal core PCB (MCPCB) that uses copper core as the base substrate. Among all of the PCB types, copper clad pcb is well-known for its extreme high thermal conductivity, which enables to achieve to 401W/m.K, that’s why some people think it is the king of the metal core PCB.

Copper-based PCB consists of three layers: copper foil layer, dielectric layer and base copper layer. Copper foil layer is the electric layer, which is mainly used for components electric connection. Dielectric layer is made by insulation material, so it also called insulation layer. Though it is function as insulation, it has good heat transfer capacity. The base copper layer is the support stone for the whole PCB. Copper core PCB is commonly used in LED lighting and other applications where need good heat dissipation.

What is Heavy Copper PCB?

Heavy copper PCB doesn’t have a clear definition in IPC standard, it is a kind of special PCB just like HDI PCB and extra thin PCB. Generally, for copper thickness equal or exceed 3ounces will be default as heavy copper pcb. For those copper thickness ranges from 20~200ounces is classified as extreme heavy copper PCB.

The base substrate of heavy copper PCB can be FR4 material or aluminum, instead of copper base. This is a significant difference between copper pcb and heavy copper pcb. Heavy copper normally used for a various product but not limited to: high power distribution, bas bur, planar transformers, power convertors, and so on. Due to it enables to carry high current and provide high power, people also called it power supply PCB and high-power PCB.

Differences Between Copper PCB and Heavy Copper PCB?

Except the structural composition, there are still some other differences between the copper core circuit board and heavy copper board. Let’s dive into together.

Copper Thickness

Copper core PCBs typically have thinner copper traces, whereas Heavy Copper PCBs have significantly thicker copper layers. If the trace width is certain, increasing the copper thickness is equivalent to increasing the section area of the circuit, so that it can carry more current.

Current-Carrying Capacity

Copper-based circuit boards are suitable for low to medium current applications. In contrast, Heavy Copper PCBs have thicker copper layers, which enables to handle higher currents without overheating. That’s why it is recommended heavy copper circuit board for high power electronics and high-power applications such as electric car.

Heat Dissipation

Actually, both of them are good in heat dissipation capabilities. But due to the copper clad circuit board is made by copper base, while heavy copper printed circuit board uses epoxy resin or aluminum as the base material, copper core PCB is superior to heavy copper PCB in heat dissipation. So, if your application requires better heat transfer but no need to carry higher power, copper core board is the go-to-choice.

Cost Effective

Among the various metal core PCBs, copper core PCB is the most expensive since the copper core itself is expensive, around 6-7 times than the aluminum core PCB.

Heavy copper PCB also is expensive since it has complex manufacturing processes and thick copper layers. But its price mainly depends on how thick copper thickness it needs. So comprehensive consideration, heavy copper pcb is the most cost-effective.

Applications

Copper PCBs are well-suited for smaller consumer electronics, where cost is a significant factor, and heat generation is minimal.

Heavy Copper PCBs are used in power electronics, automotive applications, and industrial equipment, where high current handling and heat management are essential.

Choosing the Right PCB for Your Project

When choosing between Copper Core PCBs and Power Supply PCBs, consider the following factors:

Your project’s power requirements

Thermal management needs

Budget constraints

Durability and expected lifespan

By evaluating these aspects, you can make an informed decision on which type of PCB is the best fit for your project.

In summary, the choice between Copper PCBs and Heavy Copper PCBs depends on the specific requirements of your electronic project. Copper PCBs are suitable for low to medium current applications with minimal heat generation. On the other hand, Heavy Copper PCBs offer higher current-carrying capacity and superior heat dissipation, making them ideal for high-power applications. Assess your project’s needs carefully to determine which type of PCB will serve you best.

What is Metal Core PCB?

It is a type of printed circuit board that uses metal material as the heat dissipation layer, commonly used in LED and other high-power electronic products. There are many types of metal core PCB, among which the most common one is aluminum PCB, which has a thermal conductivity of about 1W, suitable for low-power LED lamps.

However, with the development of high-power electronic products and high-frequency PCBs, aluminum PCBs can no longer meet the requirements of heat dissipation and volume. Therefore, more and more products choose copper PCB, which has a thermal conductivity of up to 400W, 400 times that of aluminum PCB. But ordinary copper PCB also has a drawback, that is, its circuit layer and heat layer are on the same layer, which requires connecting the beads and the heat layer through an insulating thermal conductive material, which will reduce the thermal efficiency. To solve this problem, a more advanced copper PCB structure has emerged, called thermal-electric separation copper PCB or SinkPad PCB.

Introduction to Thermal-electric Separation Copper PCB

The feature of thermal-electric separation copper PCB is that its circuit layer and heat layer are on different layers so that the beads can directly contact the heat layer, achieving zero thermal resistance heat dissipation. This structure can greatly improve the luminous efficiency and lifespan of the beads, and reduce light decay and heating. Thermal-electric separation copper PCB is very suitable for single high-power beads, especially the COB package, which can make the lamp achieve better effects. In addition, thermal-electric separation copper PCB can also be made into different shapes and structures according to different design needs, such as copper protrusions, copper recesses, parallel heat dissipation, etc.

Below is the structure diagram of ordinary copper PCB and copper substrate bump thermoelectric separation as an example to give you a more intuitive understanding of the advantages of thermoelectric separation copper substrate processing technology.

From the ordinary copper PCB diagram on the left, it can be seen that the heat dissipation needs to pass through the insulating and thermally conductive material (purple part in the picture), which is more convenient to process. However, after passing through the insulating and thermally conductive material, the thermal conductivity is not so good. This kind of suitable for low-power LED lights, which is enough.

If the heat dissipation requirements are very large on automotive LED lamp beads or high-frequency PCBs, both normal aluminum PCB and copper core PCB cannot meet the requirements. It is common to use thermoelectric separation of copper substrates. Because the circuit trace and thermal layer are on the different layers, the thermal layer part directly contacts the LED beads (as shown on the right side of the picture above) to achieve the best heat dissipation (zero thermal resistance) effect.

Besides, there are also many various surface treatment options for the thermal electric separation copper PCB, such as OSP, immersion gold, ENIG, immersion silver, silver plating, ENEPIG, etc. It can be carried out according to different needs, and the surface treatment layer and lifespan are reliable.

Who Can Make Thermal-electric Separation Copper PCB for You?

When you are considering to sample or order thermal-electric separation copper PCBs, it is recommended to choose Best Technology. Best team is a professional PCB manufacturer who specializes in PCB manufacturing for over 17 years of experience and provides excellent before and after-sales service. Now, Best Technology highly recommends thermal-electric separation copper PCB for you, and the price is very favorable right now. And we promise that we will make satisfactory thermal-electric separation copper PCB for you with the fastest speed and the highest quality. This is what we are proud of.

If you have any questions or comments about thermal-electric separation copper PCB or more information about our company, please feel free to contact us or e-mail us at sales@bestpcbs.com. We will serve you wholeheartedly.

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