Aluminium clad PCBÂ is widely chosen for applications that demand high thermal performance, durability, and stable operation under tough conditions. Whether you’re designing LED lighting systems or power converters, aluminium PCBs can offer better heat dissipation and mechanical support compared to traditional boards.
Best Technology is the primary custom MCPCB manufacturer in China, providing quick aluminium clad PCBprototype, fabrication, and assembly services in a very large market. We have our factory conforming with ISO 9001, ISO 13485, IATF 16949, AS9100D, UL, REACH, and RoHS. We have a competitive edge in quality control through improved manufacturing processes as well as through sophisticated inspection equipment. It would be nice if you could share your request for new enquiries with our team at sales@bestpcbs.com, then we could share the quote specifically.
What is Aluminium Clad PCB?
An aluminium clad PCB consists of a thin layer of thermally conductive dielectric material, laminated between a copper circuit layer and an aluminium base. This structure helps conduct heat away from critical components. It’s often used in high-power applications where heat control is essential.
What is the Difference: Aluminum PCB vs FR4?
FR4 is a standard fiberglass material used in many PCBs. In contrast, aluminium clad boards use metal for the base, offering superior heat conduction. Aluminium boards are more robust, but FR4 is flexible for complex layer designs. Choosing between them depends on your projectâs thermal needs and mechanical demands.
What is Aluminium Clad PCB Price?
Aluminium clad PCB price depends on board size, copper thickness, aluminum grade, and complexity. Although it may cost more than FR4 in raw material, it saves costs in heat sinks and boosts durability. For cost-effective prototypes and small runs, Best Technology offers competitive pricing and fast delivery.
What are Metal Clad PCB Specifications?
Key specifications of metal clad PCBs can vary depending on the application, but the typical ranges include:
Base Material: Commonly used aluminium alloys are 5052 and 6061, both offering good strength and thermal properties. While 3003 can be used, it is less typical due to its lower mechanical strength and thermal conductivity.
Thermal Conductivity: Standard aluminium clad PCBs offer thermal conductivity between 1.0 to 2.0 W/mK. Higher values, such as 3.0 W/mK, are available but usually require special high thermal conductivity materials, which may increase cost.
Copper Thickness: The copper layer usually ranges from 1oz to 6oz. The 1oz to 3oz range is most common, but higher thickness is possible for heavy current applications.
Board Thickness: Standard thickness ranges from 0.8mm to 3.2mm, but thinner boards, such as 0.6mm, can also be manufactured based on project needs.
Surface Finish: Typical surface treatments include HASL (Hot Air Solder Leveling), ENIG (Electroless Nickel Immersion Gold), and OSP (Organic Solderability Preservative). The choice depends on the specific assembly process and performance requirements.
These specifications allow metal clad PCBs to deliver efficient heat management and maintain structural integrity under demanding conditions. However, values should be tailored to suit the productâs real-world operating environment for best results.
What is Delamination on an Aluminum Clad PCB?
Delamination refers to the separation between layers. On aluminium boards, it can happen due to poor lamination or thermal stress. Using high-quality bonding materials and strict process control helps avoid this issue. Best Technology uses advanced lamination techniques and thermal cycling tests to ensure reliability.
What is the Purpose of Clad Aluminum?
Clad aluminum serves two key purposes: mechanical strength and heat management. It acts as a heat sink, drawing heat away from components. It also adds rigidity, which is helpful in high-stress environments such as automotive and industrial controls.
What are the Advantages of Aluminum PCB Material?
Aluminium PCB material offers several benefits:
Excellent thermal conductivity
Improved durability and support
Reduced need for additional heat sinks
Cost-effective in high-power applications
Lightweight yet strong structure
These advantages make aluminium PCB board ideal for LED lighting, power electronics, and automotive sectors.
What is Aluminium PCB Board Used For?
Common uses include:
LED lighting systems
Power supplies and inverters
Automotive lighting and control systems
Solar panels and power modules
The aluminium PCB board for LED is especially popular due to its ability to manage high heat from LED chips efficiently.
How to Ensure Quality During Aluminium PCB Manufacturing Process?
Quality control is key. Steps include:
Material inspection â Ensure consistent aluminium quality
Precise drilling and etching â Maintain tight tolerances
Thermal testing â Validate heat transfer capabilities
Visual inspection â Check for delamination or cracks
Best Technology uses MES systems for full traceability. Our in-process monitoring ensures every board meets strict quality standards, reducing defects and customer returns.
Why Choose Best Technology for Aluminium PCB Board for LED?
Customers often face issues like delayed delivery, unstable quality, or poor communication from suppliers. At Best Technology, we address these problems with clear solutions:
Fast Prototyping: Quick turn services to meet tight deadlines
Stable Quality: Certified by ISO9001, ISO13485, and IATF16949
24/7 Technical Support:Â English-speaking engineers and responsive support
Customization:Â Flexible for small or large volume, special designs welcomed
We offer aluminum PCB enclosures, full assembly, box build, and testing services to simplify your project workflow. With over 1700 satisfied global clients, weâve built a reputation for on-time delivery and reliable product performance.
In closing, choosing the right partner for your aluminium clad PCB needs can make or break your project timeline and budget. Best Technology offers a complete solution â from prototype to final assembly. We understand your need for speed, quality, and clear communication. With rigorous quality control and stable manufacturing process, we help reduce risks and support your success. If you have enquiries concerning aluminium clad PCB, just let us know at sales@bestpcbs.com or +86-755-2909-1601. We will try our best to meet your requirements. Any enquiry made always gets our response quickly.
When it comes to managing heat in high-power electronic devices, Metal Core PCBs (MCPCBs) are the go-to solution. These boards use a metal baseâtypically aluminum or copperâto efficiently dissipate heat for LEDs, power modules, and automotive systems. However, the effectiveness of an MCPCB depends heavily on the material chosen for its core and dielectric layers.
At Best Technology, we specialize in custom MCPCB fabrication using materials from leading global brands like Laird, Bergquist, and Ventec. Whether you need aluminum-based MCPCBs for LED lighting or copper-core boards for power electronics, we offer full support from material selection to prototyping and mass production. In this blog, we will share some information about metal core PCB materials, help you to understand MCPCB from the inside to out.
What Is Metal Core PCB?
A metal core PCB (MCPCB) is a printed circuit board that uses a metal base instead of traditional fiberglass (FR4). This metal base acts as a heat spreader, drawing heat away from components that generate significant thermal energy during operation.
In a typical MCPCB, the structure includes three key layers:
Copper Circuit Layer â for electrical connections.
Dielectric Layer â an insulating layer that separates the copper from the metal core, allowing heat transfer but preventing electrical conduction.
Metal Core (Base Layer) â typically aluminum, copper, or stainless steel, used to conduct heat away from the board.
These PCBs are engineered to handle thermal management more efficiently than standard PCBs. As electronic devices become more compact and powerful, effective heat dissipation becomes more important, and MCPCBs offer a practical solution.
Common Metal Core PCB Materials
There are several options when it comes to metal core PCB material, each with its own unique benefits. The choice depends on factors like thermal requirements, mechanical strength, weight, and budget.
1. Aluminum Core
Aluminum is the most commonly used metal core material in MCPCBs. It is lightweight, cost-effective, and has good thermal conductivityâtypically around 205 W/m·K. Aluminum cores are ideal for LED lighting, consumer electronics, and automotive circuits where heat must be dissipated efficiently, but extreme thermal loads are not present. The commonly used aluminum core PCB in Best Technology is 5052, 6061, 3003, here is the datasheet of them:
Property
6061 Aluminum
5052 Aluminum
3003 Aluminum
Material Type
Al-Mg-Si
Al-Mg
Al-Mn
Tensile Strength (MPa)
290 â 350
190 â 260
130 â 200
Yield Strength (MPa)
240
160 â 200
115 â 150
Elongation at Break (%)
10 â 17
12 â 20
15 â 20
Thermal Conductivity (W/m·K)
167
138
159
Density (g/cmÂł)
2.70
2.68
2.73
Melting Point (°C)
582 â 652
607 â 650
643 â 657
2. Copper Core
Copper is used where superior heat dissipation is needed. It has excellent thermal conductivityâaround 385 W/m·Kâand is suitable for high-power applications such as power supplies, industrial equipment, and RF systems. While it offers the best performance in terms of heat transfer, it is also heavier and more expensive than aluminum.
3. Stainless Steel Core
Stainless steel is rarely used, but it can be found in certain niche applications where corrosion resistance and mechanical strength are more important than thermal performance. Its thermal conductivity is much lower, around 16 W/m·K, making it suitable only for specific use cases.
Metal Core PCB Material Manufacturers
When choosing a metal core PCB manufacturer, itâs important to work with companies that supply high-quality materials and have a track record of consistency and reliability. Below are some of the leading manufacturers of metal core PCB materials that we cooperating:
Bergquist (Henkel)
Ventec
Polytronics (Taiwan)
Boyu (China)
Laird Technologies
Totking (China)
Dupont Clamcool
XianYang Bode electronic
Why Thermal Conductivity Is Important in MCPCB?
The thermal conductivity of a material refers to the amount of heat it can transfer under stable conditions. Specifically, for a 1-meter-thick material, if the temperature difference between two surfaces is 1°C, and heat transfer occurs through 1 square meter within 1 hour, the quantity of heat transferred is expressed in W/m·K (watts per meter-kelvin). For practical use, K (kelvin) can often be replaced by °C.
The thermal conductivity value depends on the materialâs composition, density, moisture content, and temperature. Materials with lower density or non-crystalline structures tend to have lower thermal conductivity, while materials with higher density and metallic bonding structures transfer heat more efficiently.
Generally, materials with low thermal conductivity are referred to as thermal insulators, and those with a conductivity below 0.05 W/m·K are called high-efficiency insulation materials. In contrast, metals typically exhibit high thermal conductivity, which makes them ideal for use in metal core PCBs.
Thermal Conductivity of Common Metals Materials
Metal
Thermal Conductivity (W/m·K)
Silver
429
Copper
401
Gold
317
Aluminum
237
Iron
80
Lead
67
Zinc
34.8
As seen in the table above, silver has the highest thermal conductivity, followed by copper and gold. However, due to cost and practicality, copper and aluminum are the most commonly used metals in MCPCBs. Aluminum strikes a balance between cost, weight, and thermal performance, while copper is chosen for extreme thermal demands.
1W vs 2W vs 3W Thermal Conductivity Differences
When evaluating MCPCB materials, it’s essential to consider not only the core metal but also the thermal conductivity of the dielectric layer. This layer sits between the copper circuitry and the metal base. In the metal core pcb manufacturing, the commonly used dielectric layers are 1W, 2W and 3W.
1W/m·K: Basic dielectric material, suitable for low-power circuits and LEDs with minimal heat output.
2W/m·K: Offers moderate thermal performance, ideal for mid-power LEDs and general electronics.
3W/m·K or higher: Designed for high-power LEDs or circuits that generate significant heat, ensuring efficient transfer to the metal core.
Choosing a higher thermal conductivity dielectric can greatly reduce thermal resistance, leading to better overall cooling performance. But not the higher the better, it should depends on your specific demands.
Aluminum PCB vs Copper Core PCB
When comparing aluminum PCBs and copper core PCBs, the main differences come down to thermal performance, cost, and application needs. Both are types of metal core PCBs (MCPCBs), but they serve different purposes depending on how much heat your circuit generates and how much budget you have.
Aluminum PCB is the most commonly used metal core because it offers a good balance of performance, weight, and affordability. It provides moderate thermal conductivity (around 237 W/m·K) and is suitable for many applications, especially LED lighting, consumer electronics, and automotive circuits where heat is present but manageable. Aluminum is also lightweight, making it easier to handle and mount, especially in devices where weight matters.
Copper core PCB, on the other hand, offers superior thermal conductivity (around 401 W/m·K if used directly thermal path technology), nearly double that of aluminum. This allows it to handle more heat, which is crucial in high-power electronics, RF systems, and industrial power converters. However, copper is heavier and more expensive, so it’s typically used only when the highest level of heat dissipation is required.
Aluminum PCBCopper Core PCB
Can I Use Aluminum PCB in High Power LED Lighting?
Yes, aluminum PCBs are widely used in high-power LED lighting, especially when paired with high thermal conductivity dielectric materials. These boards effectively dissipate heat away from LEDs, preventing overheating and maintaining light output stability.
However, the design must ensure:
Adequate heat spreading area
Proper thickness of aluminum core (typically 1.0mm to 1.6mm)
High-quality dielectric layer with 2W or 3W thermal conductivity
In cases where LEDs generate extreme heat, consider using copper MCPCBs or combining the aluminum core with external heat sinks for better performance.
How to Choose the Right MCPCB Material for LED Projects?
Selecting the correct metal core PCB material for your LED project involves analyzing the following:
Thermal Output of LEDs
Higher wattage LEDs generate more heat. For low-power LEDs, aluminum with 1W/m·K dielectric is sufficient. For high-power LEDs, choose aluminum or copper with 2Wâ3W dielectric.
Mechanical Requirements
If the PCB must endure vibration or mechanical stress (e.g., automotive lighting), choose thicker copper for added durability.
Budget Considerations
Aluminum offers a cost-effective balance between performance and price. Copper is more expensive and should be reserved for projects where thermal performance cannot be compromised.
Weight Constraints
In portable or ceiling-mounted LED systems, lightweight aluminum helps reduce the overall weight of the fixture.
Metal Core PCB Applications
LED Lighting: Used in street lights, automotive lights, grow lights, and flood lights to ensure LEDs stay cool.
Power Electronics: Found in motor controllers, inverters, and converters to handle large currents and heat.
Automotive: Used in ECUs, headlights, and battery systems for reliable performance in harsh environments.
Telecommunications: Applied in RF modules, power amplifiers, and antenna systems.
Consumer Devices: Used in high-performance audio systems and power adapters.
Best Technology â Your Online Partner in MCPCB Manufacturing
At Best Technology, we specialize in the design and production of metal core PCBs for various industries. Whether you need aluminum or copper-based boards, we deliver customized thermal solutions to meet your specific project needs. By choosing Best Technology, you can enjoy:
How to find a MCPCB fabrication factory?â This guide explains metal core PCB manufacturing, its benefits, processes, and how to select reliable suppliers.
Are you worried about these issues?
How long can your product run stably at high temperatures?
Do urgent orders always put you in a passive position?
How to balance cost and price?
Best Technology Can Provide:
Customized thermal management solution: Adopt gradient thermal conductive structure design, which can reduce the junction temperature of the device by 25â+ and extend the service life by 3 times.
72-hour express delivery: reserve special production line capacity, and the expedited order can be shipped in as fast as 3 days (including quality inspection).
Value engineering cost optimization: Through material combination innovation and process simplification, we can help customers reduce costs by 15% while ensuring IPC standards.
Feel free to contact us if you have any inquiry for MCPCB: sales@bestpcbs.com.
What Is MCPCB Fabrication?
MCPCB fabricationinvolves manufacturing circuit boards with a metal core (typically aluminum or copper) to enhance heat dissipation. The process includes bonding a thermally conductive dielectric layer to the metal base for electrical insulation, laminating a copper circuit layer on top, and etching circuit patterns via photolithography. Vias are drilled and plated for electrical connectivity, followed by surface finishes to protect copper and ensure solderability. Designed for high-power applications, MCPCBs efficiently manage thermal stress in devices like LEDs, automotive systems, and power electronics.
Benefits of Metal Core PCB Fabrication
Superior Heat Dissipation – Metal cores (Al/Cu) conduct heat 8â12Ă faster than FR4, reducing component temperatures by up to 15°C (e.g., LEDs). Extends product lifespan and prevents thermal throttling.
Enhanced Durability – Metal substrates resist warping and vibration, ideal for automotive/industrial use. Withstands temperatures up to 120°C continuously.
Cost Efficiency – Reduces reliance on external cooling systems. Lower maintenance costs due to higher reliability (MTBF â„50,000h).
Eco-Friendly – Aluminum cores are recyclable, aligning with sustainability goals.
High-Power Performance – Handles power densities >20 W/cmÂČ (e.g., IGBT modules) without degradation.
EMI Shielding – Metal base acts as a natural shield, reducing electromagnetic interference.
Applications of Metal Core PCB Fabrication
High-Power LED Lighting – Directs heat from LEDs to metal core, preventing premature failure. Extends lifespan and reduces maintenance costs.
Electric Vehicle (EV) Systems – Cools battery modules, motor controllers, and charging units. Withstands vibration and thermal stress for reliable operation.
Renewable Energy Inverters – Enhances thermal efficiency in solar/wind inverters, minimizing energy loss and boosting ROI.
Medical Imaging & Diagnostics – Stabilizes temperature-sensitive components (e.g., lasers, sensors). Ensures precision in critical healthcare devices.
Aerospace & Defense Electronics – Resists extreme temperatures and mechanical stress in satellite/aviation systems. Maintains performance during rapid thermal cycling.
Industrial Motor Control – Manages heat from high-current motor drivers and inverters. Prevents thermal deformation, ensuring continuous operation.
5G Base Station Modules – Efficiently dissipates heat from high-frequency RF components. Maintains signal integrity and reliability in dense wireless infrastructure.
EV Charging Infrastructure – Supports high-power DC charging by rapidly conducting heat away from power electronics. Enables faster, safer charging solutions.
MCPCB Fabrication Processes
1. Design & Engineering
Use EDA tools to create PCB layout, adhering to IPC-2221 standards.
Generate Gerber files and validate through Design Rule Checks (DRC).
2. Material Preparation
Select metal substrate (aluminum/copper), insulating layer (epoxy/ceramic), and copper foil.
Cut metal base to specified dimensions.
3. Metal Substrate Treatment
Clean substrate to remove contaminants.
Apply insulating layer via coating or lamination, ensuring uniformity.
4. Circuit Layer Formation
Use photolithography to pattern copper traces:
Coat substrate with photoresist.
Expose to UV light through circuit masks.
Develop and etch to remove excess copper.
5. Lamination & Pressing
Stack layers (metal base, insulating layer, copper foil) with prepreg.
Press under high temperature/pressure to bond layers (IPC-6012 compliance).
6. Drilling & Plating
Drill via holes for interlayer connections.
Electroplate holes to deposit copper, ensuring conductivity (IPC-A-610).
7. Surface Finish
Apply surface treatment (e.g., ENIG, OSP) to protect copper and enhance solderability.
8. Testing & Inspection
Electrical test (flying probe) to verify connectivity.
AOI for defects, thermal stress test for reliability.
9. Profiling & Cutting
Route PCB to final shape, V-cut or bevel edges as needed.
10. Packaging & Shipping
Final inspection, vacuum packaging to prevent oxidation.
1. Search Online: Use Google/Bing with keywords: âMCPCB manufacturer China,â âmetal core PCB fabrication.â
2. Browse B2B Platforms: Check Alibaba International, Made-in-China, or Global Sources. Filter by Trade Assurance, UL/IPC-6012 certifications, and MOQ.
3. Attend Global Trade Shows: Visit Productronica China, HKTDC Electronics Fair, or CES to meet suppliers and inspect samples.
4. Verify Certifications: Confirm UL, ISO 9001, and IPC-6012 compliance via official databases.
5. Request Quotes: Send detailed specs (materials, layer count, thermal requirements) and ask for free prototypes + DFM feedback.
6. Audit Factories: Check production equipment (automation level), AOI/X-ray inspection, and thermal testing labs via virtual/on-site visits.
7. Prioritize Technical Expertise: Choose factories with MCPCB capabilities and experience in high-power applications (LED, automotive).
Why Choose Best Technology as MCPCB Manufacturer?
Precision Manufacturing for High-Performance MCPCBs: Specialized in production of aluminum and copper-core PCBs with ±10Όm tolerance, ensuring optimal thermal conductivity for LED, automotive, and power electronics applications.
Custom Thermal Solutions for Your Needs: Our engineers dielectric layers and metal core designs to maximize heat dissipation, with thermal conductivity ranging from 1.0W/m·K to 4.0W/m·K for stable performance in high-power environments.
24-Hour Rapid Prototyping for Critical Projects: Emergency orders processed within 24 hours, reducing time-to-market by up to 70% compared to industry standards.
Strict Quality Control for Bulk Orders: Full AOI and X-ray inspection on every bulk order, maintaining defect rates below 0.1% (industry average: 0.5%).
Factory-Direct Pricing with No Hidden Costs: Transparent pricing saves 15-30% compared to distributors, with no additional fees for design reviews or testing.
Fast Delivery with Consistent Lead Times: Standard lead times as short as 5 days (industry average: 10-14 days), with 98% on-time delivery rate.
Free DFM Analysis to Optimize Your Design: Technical team reviews designs for manufacturability, reducing production errors by up to 40%.
High-Quality Material Sourcing: Exclusively uses FR-4 and aluminum substrates from top suppliers like Rogers and Ventec for reliability.
Scalable Production Capacity: Handles orders from 10-unit prototypes to 50K+ monthly batches without compromising quality.
Our Certification & Quality Inspection
Certified & Compliant Standards: ISO 9001, ISO 13485, IATF 16949 Certified, and UL, REACH, RoHS Compliant.
AOI (Automated Optical Inspection): Detects surface defects like open/short circuits, missing components, and soldering issues.
Unlike traditional PCBs that rely on FR4 or other resin-based materials, IMS PCBs use a metal baseâtypically aluminum or copper. This base is paired with a dielectric layer and a copper circuit layer on top.
Itâs not just a circuit board. Itâs a thermal solution that keeps devices cool and running longer.
IMS PCB full form and meaning?
The full form of IMS PCB is Insulated Metal Substrate Printed Circuit Board. It’s a PCB built to move heat away from components. That means better reliability, higher efficiency, and longer lifespan for your electronic products.
In this type of PCB, the metal substrate acts as a heat spreader. The insulation layer isolates the copper circuit from the metal base, while still allowing heat to pass through. Itâs a smart design that balances performance with thermal control.
What is IMS material?
The core of every IMS PCB lies in its materials. These layers provide the best thermal and electrical performance. Hereâs what youâll find in a standard IMS stack:
Metal Base Layer: Usually aluminum for cost-efficiency and light weight. Copper is also used when more heat dissipation is required.
Dielectric Layer: A thermally conductive but electrically insulating material. It transfers heat from the circuit layer to the metal base.
Copper Circuit Layer: This is where the actual electrical routing happens. It’s similar to traditional PCB copper layers but optimized for thermal contact.
These three layers form the structure of IMS. The combination is compact, efficient, and powerfulâespecially in LED lighting, automotive electronics, and power converters.
The insulation layer, in particular, must handle high thermal loads while resisting electrical breakdown. Advanced IMS designs often use proprietary dielectric materials to increase thermal conductivity and reduce overall thickness.
How thick is a IMS PCB?
The thickness of an IMS PCB depends on the application. But typically, hereâs what you can expect:
Metal base layer: 0.5mm to 3.2mm
Dielectric layer: 0.03mm to 0.2mm
Copper layer: 0.035mm to 0.2mm
The total thickness usually ranges from 0.8mm to 3.5mm. For LED lighting and compact modules, thinner IMS boards (like 1mm) are common. But in power-heavy designs, thicker boards provide the support and thermal capacity needed.
Some custom builds even exceed 3.5mm if the heat demands are extreme. A thicker aluminum layer enhances mechanical strength and heat dissipation, but it also increases weight and cost. So choosing the right thickness is a balance of thermal needs and design efficiency.
What is the difference between FR4 and IMS PCB?
FR4 PCBs use glass-reinforced epoxy as their core. They are great for general electronics. But FR4 struggles with thermal stress. When high-power components run hot, FR4 doesn’t cool them fast enough. That leads to overheating and failure.
IMS PCBs, on the other hand, are built for thermal performance. The metal base acts like a built-in heat sink. It draws heat away from critical components and spreads it out. That protects the electronics and improves reliability.
Feature
FR4 PCB
IMS PCB
Core Material
Epoxy-based fiberglass
Metal (usually aluminum)
Thermal Conductivity
~0.25 W/mK
1.0â9.0 W/mK or more
Heat Dissipation
Limited
Excellent
Cost
Lower
Slightly higher, but worth it
Mechanical Strength
Moderate
Stronger due to metal core
For everyday consumer electronics, FR4 is fine. But for power-hungry devices, IMS PCBs offer unmatched reliability.
2 layer IMS PCB vs Multilayer IMS PCB
While single-layer IMS boards are most common, especially in LED lighting, 2-layer and multilayer IMS PCBs are gaining ground in complex applications.
2-layer IMS PCB means there are copper circuits on both sides of the dielectric layer, with one metal core layer. These offer more routing options while still allowing good heat dissipation.
Multilayer IMS PCBs, on the other hand, can include several copper layers, separated by insulation, and only one side is connected to the metal base for heat transfer. This allows for complex routing and high component density while keeping thermal control.
Benefits of 2-layer IMS PCB:
Better circuit flexibility
Moderate thermal management
More design freedom
Benefits of Multilayer IMS PCB:
High circuit complexity
Suitable for dense power modules
Thermal performance still superior to FR4
If you’re building a simple LED module, a single or 2-layer IMS may be enough. But if you’re designing a power controller, communication device, or automotive ECU, multilayer IMS is often necessary.
IMS PCB stackup: What to know?
Stackup design is more than just layers, it defines how your board handles heat, power, and performance. A typical IMS PCB stackup looks like this:
Copper circuit layer
Dielectric insulation layer
Metal substrate (usually aluminum)
But thereâs room for customization. Hereâs what matters:
Copper thickness: Choose 1oz, 2oz, or more depending on current flow.
Dielectric performance: The higher the thermal conductivity (measured in W/mK), the better the heat transfer.
Metal base: Aluminum is the go-to for most. But copper or stainless steel can be used for extreme performance or rigidity.
Surface finish: Choose between HASL, ENIG, OSP, or others based on your assembly process.
Stackup choices directly affect reliability. A poor choice here means components will overheat, solder joints will crack, or performance will drop.
What are the applications of IMS PCB?
IMS PCB is widely used in high power industry.
LED lighting: Keeps high-brightness LEDs cool, extending their life.
Automotive electronics: Used in headlights, sensors, battery modules.
Power converters: Manages heat in inverters and converters.
Industrial control systems: Ensures smooth performance under high power loads.
Communication base stations: Maintains signal integrity and prevents thermal breakdown.
Why choose the right IMS PCB Manufacturer?
At Best Technology, we understand the critical role IMS PCBs play. Weâve spent years perfecting the production process, materials, and stackup customization. Every board we deliver is tested for:
Thermal conductivity
Mechanical strength
Electrical reliability
Whether you need standard single-layer boards or complex multilayer IMS PCBs, we can build it to your exact needs.
Conclusion:
IMS PCB is very important in high power electronics. From simple LED lights to advanced power modules, IMS boards keep your devices cool, stable, and efficient.
Looking for an IMS PCB manufacturer you can rely on? Contact us today at sales@bestpcbs.com
Why choose copper IMS PCB? This guide covers copper IMS PCB from design to manufacturing, highlighting superior heat dissipation, design guidelines for high-power applications, and Best Technology’s precision production capabilities.
Are you bothered by these problems?
How to break through the heat dissipation bottleneck?
How to balance cost and performance?
How to ensure signal integrity?
Best Technology can provide:
Three-dimensional heat dissipation architecture: Exclusive copper-based composite design, thermal resistance reduced by 40%, achieving a 25°C reduction in temperature rise at the same power consumption.
Optimized material cost performance: Patented copper-aluminum hybrid process, reducing material costs by 18% while maintaining thermal conductivity.
Electromagnetic compatibility integration: Built-in gradient impedance design, 5G band signal attenuation is controlled within 0.3dB.
Welcome to contact us if you have any inquiry for metal core PCB: sales@bestpcbs.com.
What Is Copper IMS PCB?
Copper IMS PCB (Insulated Metal Substrate Printed Circuit Board) is a high-performance circuit substrate constructed on a metal base (typically copper or aluminum) coated with a thermally conductive dielectric layer. It combines a copper circuit layer, a ceramic/polymer-based insulating layer, and a metal core to achieve exceptional thermal management (1-12 W/m/K conductivity), electrical insulation, and mechanical stability. Primarily used in high-power applications like LED lighting, automotive power modules, and aerospace systems, it offers 100x lower thermal resistance than FR4 while enabling efficient heat dissipation through its metal core structure.
What Is Stackup of Copper IMS PCB?
Copper IMS PCB Stackup Structure
Copper Base Plate
Material: High-purity electrolytic or rolled annealed copper (1â5 oz thickness) for superior thermal conductivity (398 W/m·K).
Function: Primary heat dissipation layer, often embedded with thermal vias to enhance heat transfer to external heat sinks.
Dielectric Insulation Layer
Material: Ceramic-filled epoxy or high-thermal-conductivity prepreg (e.g., 0.15 mm thickness with thermal resistance <0.7°C/W).
Function: Provides electrical isolation between the copper circuit and base plate while minimizing thermal resistance.
Copper Circuit Layer
Material: Thin copper foil (0.5â2 oz) for signal/power routing, processed via etching to form circuits.
Function: Conductive pathways for components, with optimized thickness balancing current capacity and signal integrity.
Solder Mask & Surface Finish (Optional)
Solder Mask: Protects copper traces and prevents solder bridging.
Surface Finish: ENIG (Electroless Nickel Immersion Gold) or HASL (Hot Air Solder Leveling) for solderability and oxidation resistance.
Design Considerations
Symmetry: Mirror-stacked layers (e.g., L1/L4, L2/L3) to prevent warping.
Thermal Vias: Embedded or plated-through vias to connect heat-generating components to the copper base.
Material Selection: High-Tg (>170°C) prepreg for stability under thermal cycling.
Exceptional Current Carrying Capacity (15A/mmÂČ)â – Supports 3x higher current density than standard FR4, reducing PCB size by 35% for equivalent power.
Thermal Expansion Matching (CTE=17ppm/â)â – Eliminates solder joint failures in thermal cycling (-40°C to 150°C), critical for automotive/industrial apps.
Built-in EMI Shieldingâ – Reduces RF noise by 40dB without additional shielding layers, ideal for 5G/RF circuits.
High-Frequency Performanceâ – Superior signal integrity for GHz-range applications with minimal signal loss.
Miniaturization Potentialâ – Supports 0.1mm dielectric layers and microvias for chip-scale packaging in medical/portable devices.
Long-Term Reliabilityâ – Zero oxidation risk and 100% recyclability reduce lifetime costs by 18% vs. aluminum.
What Are Applications of Copper IMS PCB?
Automotive: Reduces overheating in LEDs/batteries – longer lifespan, lower maintenance.
Renewable Energy: Cuts heat loss in solar/wind systems – boosts efficiency, lowers costs.
Use thick copper foil (2oz/3oz or higher) to handle high current densities.
Prioritize low-thermal-resistance dielectric layers (e.g., ceramic-filled polymers) to maximize heat transfer to the copper base.
2. Thermal Management
Place heat-generating components (e.g., MOSFETs, LEDs) directly over the copper base for direct heat dissipation.
Add thermal vias under hot components to channel heat vertically to the copper layer.
Avoid thermal isolation; ensure continuous copper paths for heat flow.
3. Current Path Optimization
Design wide, short traces for high-current paths to minimize resistance and IÂČR losses.
Use parallel traces or polygon pours to distribute current evenly.
Avoid sharp bends (â„90°) in high-current traces to reduce inductance and hotspots.
4. Layer Stackup
Prioritize a 2-layer stack: copper base (bottom), dielectric layer, and copper top layer.
For complex designs, add internal copper layers with prepreg insulation, ensuring thermal vias connect all layers.
5. Mechanical Stability
Maintain symmetry in layer stackup to reduce warping during reflow.
Use heavy copper (â„3oz) for rigid base support; avoid over-etching thin features.
6. Component Placement
Isolate high-power components from sensitive analog/digital sections to prevent thermal interference.
Leave spacing around heat sinks or mounting holes for airflow or mechanical fixation.
7. Testing & Validation
Perform thermal simulation (e.g., ANSYS Icepak) to verify heat dissipation under max load.
Test under worst-case power conditions to ensure junction temps stay below component limits.
Notes: Balance thermal performance, electrical efficiency, and mechanical reliability. Prioritize direct heat paths, robust current handling, and material durability for high-power resilience.
Copper IMS PCB Manufacturing Processes
1. Material Preparation: Start with a copper base plate, a thermally conductive dielectric layer (e.g., ceramic-filled polymer), and top-layer copper foil. Materials are selected for thermal performance and durability.
2. Lamination: Bond the layers under controlled heat and pressure. The copper base, dielectric, and top foil are fused to create a rigid, thermally efficient structure.
3. Drilling: Precision-drill vias and through-holes. Clean debris thoroughly to ensure clean plating surfaces.
4. Plating: Apply electroless or electrolytic copper plating to coat hole walls, enabling vertical electrical connections between layers.
5. Etching: Use photoresist and chemical etching to remove excess copper from the top layer, leaving defined circuit traces.
6. Surface Finish: Apply finishes like ENIG, OSP, or immersion silver to protect exposed copper and enhance solderability during assembly.
7. Cutting & Profiling: Cut the panel into individual PCBs. Machine edges (e.g., V-score, routing) to meet required dimensions and shapes.
8. Quality Testing: Perform electrical tests (continuity, isolation), thermal stress tests (e.g., reflow cycles), and visual inspections to ensure reliability and performance.
Why Choose Best Technology as Copper IMS PCB Manufacturer?
LED MCPCB board is a metal-based printed circuit board designed specifically for LEDs. Its aluminum or copper substrate is combined with an insulating thermal conductive layer and a copper foil circuit to quickly conduct heat away from the chip, improve lighting efficiency and life, and is widely used in high-power COB, car lights, street lights and backlight modules.
Unlike standard circuit boards, an MCPCB LED board has a special metal base, often aluminum. This metal base isnât just there for supportâitâs a built-in cooling system.
Heat is the enemy of LEDs, and the metal in an MCPCB helps pull heat away from the LEDs, keeping them cool, strong, and long-lasting.
MCPCB boards are commonly used in LED bulbs, light strips, automotive lights, floodlights, and backlit panels. The key reason is simpleâthey work better under heat, last longer, and deliver brighter, more stable light.
What is the full form of Mcpcb LED?
MCPCB LED stands for Metal Core Printed Circuit Board for Light Emitting Diode applications. Hereâs the breakdown:
M = Metal
C = Core
P = Printed
C = Circuit
B = Board
These boards have one core purposeâto drive LED lighting performance to a higher level. The aluminum (or sometimes copper) base inside the board spreads heat away from the light source, keeping everything running smoothly.
Copper Foil Layer: the copper layer used is relatively thicker than normal CCLs ( 1oz-10oz). A thicker layer of copper means a larger current carrying capacity.
Dielectric Layer: the Dielectric layer is a thermally conductive layer and is around 50ÎŒm to 200ÎŒm thick. It had a low thermal resistance and it suitable for its application.
Aluminum Base: The third layer is the aluminum base which is made up of aluminum substrate. It has a high thermal conductivity.
What are the types of LED board in lighting?
Lighting applications demand variety. LED PCBs come in many forms to meet these needs.
Standard FR4 LED PCBs: Made with traditional fiberglass, theyâre good for low-power lights. But they struggle with heat.
Aluminium LED PCBs: The most common metal core PCB used in LED applications. Excellent thermal performance. Lightweight, cost-effective.
Copper Core LED PCBs: Used when extreme heat dissipation is needed. Stronger than aluminum but also more expensive.
Flexible LED PCBs: Ideal for curves and corners. Used in design-focused lighting.
Ceramic LED PCBs: Rare, but they handle high heat exceptionally well.
Among these, MCPCB LED boardsâespecially aluminum onesâlead the industry for high-lumen applications due to their superior heat control.
How is MCPCB LED board assembled?
The assembly of an LED MCPCB board involves several precise steps:
Solder Paste Application: A layer of solder paste is applied onto the pads of the metal core PCB using a stencil.
Pick & Place Process: LED chips and other surface-mount components are placed onto the soldered areas using high-speed machines.
Reflow Soldering: The board goes through a reflow oven. Heat melts the solder paste and secures the components in place.
Inspection: Automated Optical Inspection (AOI) checks for soldering accuracy. This step ensures every component is perfectly aligned and attached.
Testing: Final tests simulate real-life lighting conditions to verify the LED PCBâs performance.
Assembly must be precise and efficient. And with aluminium PCB bases, the process also requires care to avoid overheating during reflow.
How to test led circuit board?
Testing is where quality becomes visible. Hereâs how to ensure every MCPCB board performs as expected:
Visual Inspection: This checks for soldering issues or misplaced components.
Multimeter Testing: This tool checks whether power is flowing correctly across the circuit.
Functional Testing: Apply voltage. Does the LED light up properly? Are brightness levels correct?
Thermal Imaging: Some use infrared cameras to check for hotspots that indicate poor heat dissipation.
Reliable mcpcb led boards pass these tests with ease, offering users the confidence of durability and safety.
How does an aluminium PCB help LED lights?
Aluminum PCBs are the key enabler behind high-performance LED lighting. Hereâs why they matter:
Heat Dissipation: Aluminium spreads heat away from the LED chip faster than traditional materials.
Durability: Aluminium boards are solid. They withstand physical and thermal stress better than fiberglass.
Lightweight: Despite their strength, aluminium PCBs are lightâperfect for compact or portable lighting products.
Longer Lifespan: Cooler LEDs mean longer-lasting lights. An LED on an aluminium PCB can last 50,000+ hours with minimal loss in brightness.
Energy Efficiency: Efficient cooling means less wasted energy, which boosts overall performance.
What is the difference between PCB and Mcpcb?
Though they look similar, PCB and MCPCB are built for very different challenges.
Base Material:
PCB: Uses FR4 fiberglass or plastic.
MCPCB: Uses aluminium or copper for better thermal control.
MCPCBs cost more, but offer superior reliability for high-power devices.
Applications:
PCB: Best for low-power electronics.
MCPCB: Ideal for LEDs, power supplies, automotive lights, and high-intensity applications.
So, while both have their place, when heat is involved, MCPCB wins.
Is MCPCB LED board better than FR4?
Yes, and itâs not even close in most LED applications.
FR4 PCBs are fine for low-power, low-heat environments. But when you add in high-lumen LEDs, the heat spikes. FR4 canât handle that for long.
MCPCB LED boards step in with built-in heat control, thanks to their metal core. They maintain brightness, extend lifespan, and prevent failure. Thatâs why most LED manufacturers rely on aluminium MCPCBs for performance lighting.
In short, if your LEDs matter, MCPCBs deliver.
What affects LED PCB board price?
The price of a led mcpcb board can vary widely. Hereâs what affects it:
Material Type: Aluminium costs more than FR4, copper even more.
Board Thickness: Thicker boards handle heat better but cost more to produce.
Thermal Conductivity Rating: The better the heat transfer, the higher the price.
Board Size and Layers: Larger and multi-layer boards need more material and time.
Design Complexity: More components, special shapes, and tight tolerances mean higher costs.
Volume: Bulk orders usually lower the mcpcb led board price.
Surface Finish: ENIG, HASL, or OSP finishes affect both durability and cost.
Assembly Services: Adding LED pcb assembly raises prices but saves time and effort.
Still, when you think long-term, the right LED PCB saves money, longer life, fewer failures, and better performance.
Conclusion:
MCPCB LED boards, especially those made with aluminium, are the heartbeat of modern lighting. Theyâre engineered to handle heat, boost brightness, and outlast traditional boards.
Aluminium PCB is the most popular type, balancing cost and performance. Compared to FR4, MCPCB boards are simply better for LEDs.
For more details, quotes, or expert guidance on choosing the right LED MCPCB board, contact our team at sales@bestpcbs.com
Copper IMS PCBÂ costs can climb fast, especially in high-power or LED projects. Yet, you donât have to accept high pricing. This blog will walk you through practical ways to cut your copper IMS PCB costs by 25%, without losing quality.
Best Technology is a leading IMS PCB manufacturer, delivering Copper IMS PCB and aluminum IMS PCB prototypes, fabrication, assembly, and box build service tothe increasingly developing world of electronics. Most of our engineers have worked at Best Technology for over 10 years. We can apply our empirical knowledge to do DFM reviews and recommend the most suitable material that meets your performance target.
Moreover, supporting low to medium volume orders and short lead times gives us a competitive edge in world markets. Per our company policy, there are normally 2-3 weeks for the complex boards, and we will adhere to this policy from the top down without any excuses. This saves you the headache of the MOQ barrier and unpredictable and long times. Whatever questions or enquiries you have about copper IMS PCB will be answered by our team, pls do call at +86-755-2909-1601 or sales@bestpcbs.com.
What is a Copper IMS PCB?
A copper IMS PCB stands for insulated metal substrate circuit board with a copper base. Unlike aluminum IMS boards, copper offers better thermal conductivity. These boards are used in power electronics, LED lighting, and automotive systems where heat control matters most.
What Are Other Names for Copper IMS PCB?
Besides copper IMS PCB, people call them copper core PCBs, copper metal core boards, or copper-based IMS boards. Sometimes, they are referred to as thermal copper PCBs due to their role in heat dissipation.
Are IMS Printed Circuit Boards Made of Copper?
Not all IMS printed circuit boards use copper. Many are made with aluminum. However, when thermal demand is high, copper is preferred for its superior conductivity and durability. So, copper IMS PCB is often used in demanding environments.
What Is the Difference: Copper IMS PCB vs Copper MCPCB?
Many people think copper IMS PCB and copper MCPCB are the sameâbut they are not exactly equal. Letâs break it down.
Key Differences:
Feature
Copper IMS PCB
Copper MCPCB
Meaning
Copper board with insulation layer
Copper board, may or may not have insulation
Structure
3 layers: Circuit + Insulation + Copper Base
May have only Copper Base and Circuit
Focus
Highlights heat control + insulation
Highlights metal core
Usage
High voltage, high power (e.g., LED, power)
General applications, lower insulation need
Relationship
A type of MCPCB with insulation
Broader group, includes IMS boards
Simple Summary:
Copper IMS PCB = special copper MCPCB that must have an insulation layer.
Copper MCPCB = copper metal board, not always insulated.
So, every copper IMS PCB is a copper MCPCB, but not every copper MCPCB is an IMS PCB.
This difference matters when your project needs both heat control and electrical insulationâthen, go for copper IMS PCB.
What Temperature to Solder Copper IMS?
Copper IMS PCBs have great heat-spreading ability, but careful control during soldering is still necessaryâmainly to protect the insulation layer. Here are the key points to know:
Typical Temperature Range Soldering temperatures usually fall between 220°C and 280°C. This matches well with most lead-free solders, which melt at around 217°C to 250°C. However, always check the exact type of solder you’re using and adjust the temperature accordingly.
Insulation Layer Protection While copper spreads heat fast, the insulation layer (often made from polyimide or similar materials) can only handle 200°C to 250°C for short periods. If the temperature is too high or held too long, the insulation may delaminate or even carbonize, leading to long-term failure.
Peak Temperature Control Keep the peak soldering temperature no more than 30°C to 40°C above the solderâs melting point. For example, if your solder melts at 240°C, aim for 270°C to 280°C. This range helps prevent damage while ensuring proper solder flow.
Soldering Time Limit the soldering time to 2â4 seconds at peak temperature. But itâs not just about timeâalso manage your temperature curve, including preheating and cooling. A smooth curve helps reduce thermal stress on the insulation.
Testing Is Essential Before starting mass production, run tests. Methods like TGA (Thermogravimetric Analysis) or DSC (Differential Scanning Calorimetry) help confirm how well the insulation layer handles heat. These tests can catch weak points early.
To conclude, copper IMS PCBs need careful soldering, even though they manage heat well. Protect the insulation layer by controlling temperature and time, and always validate your process before full production. This ensures long-term reliability without hidden risks.
What Is a Copper Pour in IMS Printed Circuit Board?
In copper IMS PCBs, a copper pour is a large area of copper applied across parts of the board. It plays a key role in heat spreading and grounding, but thereâs more to understand. Hereâs what matters:
Types of Copper Pour There are two common types:
Solid Pour â a fully filled copper area, ideal for thermal management.
Grid Pour â a mesh-like pattern, mainly used to reduce EMI (electromagnetic interference) but less effective for heat.
In IMS PCBs, solid copper pour is preferred because it transfers heat better.
How It Works The copper pour connects to the copper base through thermal vias or directly, depending on design. It reduces thermal resistance, helping heat flow from hot components into the copper base. The insulation layer, typically with 1â3 W/m·K thermal conductivity, also aids this process.
Benefits for Current Flow Besides heat, copper pour can improve current flow by reducing resistance pathsâespecially useful in high-power circuits.
Cost Saving Potential By designing a smart copper pour, you may reduce or even avoid extra heat sinks. But this depends on your component layout and power density. If components are spread out, the pour helps spread heat more evenly.
EMI Consideration Copper pour also affects electromagnetic interference. A well-designed pour can shield signals and lower EMI, but poor design might cause noise issues. So, it’s important to balance thermal and electrical needs.
In a nutshell, copper pour in IMS PCBs is more than just extra copper. Itâs a tool for better thermal control, grounding, and possibly cost reduction. Using solid pour for heat and careful layout helps you get the most out of your copper IMS PCB design.
What Are the Price Differences: Copper IMS PCB vs PCB?
Copper IMS PCB is more expensive than standard FR4 PCB. The reasons include the cost of copper, complex fabrication, and thicker insulation layers. Yet, when you compare performance, especially in thermal control, copper IMS PCB often justifies its price. In the long run, it prevents failures and reduces rework costs.
What Is the Primary Role of Copper in PCB?
Copper in PCB handles both signal transmission and heat transfer. In copper IMS PCBs, copper mainly moves heat away from components. This prevents overheating and boosts lifespan. It also ensures power flows efficiently across the board.
How to Cut Copper IMS PCB Costs?
Hereâs how you can save up to 25% without losing quality:
1. Optimize Board Design
Efficient layouts cut material waste. Using the right copper thickness and pour design can save money and improve heat flow. Avoid over-designing areas where itâs not needed.
2. Use Standard Panel Sizes
Non-standard sizes increase costs. By designing copper IMS PCB that fits common panel sizes, you save on material and labor.
3. Choose the Right Manufacturer
A reliable IMS PCB manufacturer offers better pricing with quality. Best Technology offers cost-effective solutions thanks to its streamlined process and MES tracking. This prevents delays and errors, saving your time and money.
4. Order in Bulk
Higher volumes reduce unit cost. Plan your orders to maximize economies of scale.
5. Avoid Excessive Tolerances
Unneeded tight tolerances add cost. Confirm which tolerances are essential for function, and where you can relax specs.
6. Select the Right Finish
Some finishes cost more than others. Choose one that meets your needs without overpaying. HASL or ENIG may be enough for most copper IMS PCBs.
7. Plan Ahead for Assembly
Working closely with your assembler ensures smoother processes. Avoid late changes which can drive up rework costs. Early design for manufacturing reviews helps prevent this.
Why Choose Best Technology as Your Original IMS PCB Manufacturer in China?
Best Technology solves key customer problems in copper IMS PCB production.
24/7 Technical Customer Service: Many buyers face delays, inconsistent quality, or unclear communication. Our team ensures prompt support and fast feedback within 12 hours.
Premium Qualityâ IMS Board PCB: We utilize the ISO9001, IATF16949, and AS9100D systems to ensure total quality control.
Cutting-edge Material Management System: Our MES (Manufacturing Execution System) ensures complete traceability of components, preventing any mix-ups. Clients trust us for consistent quality, even in complex builds.
NO MOQ: We support both small and large volume orders with fast turnaround. Whether you need copper IMS PCBs for LED lighting or automotive, we deliver without MOQ. Our technical team works with you from start to finish, offering effective solutions instead of just the boards.
In short, Best Technology doesnât just make copper IMS PCBsâwe help you succeed in your projects with the right solutions, on time and budget.
All in all, cutting copper IMS PCB costs doesnât mean cutting corners. By focusing on smart design, choosing standard panel sizes, and partnering with the right manufacturer, you can reduce costs by up to 25%âwithout sacrificing quality or reliability. However, many buyers struggle with slow responses, poor quality control, and unclear communication. These issues not only delay projects but also lead to higher costs in the long run.
At Best Technology, we help you avoid these problems. Our professional team offers quick feedback, strict quality control, and full traceability through MES systems. We support both small and large volume orders, and weâre committed to delivering consistent, high-quality copper IMS PCBs on time. If you have new projects for enquiry, pls let us know your specific requirement at sales@bestpcbs.com, then we can quote you as rapid as we can.
If you are working on high-power electronics, LED lighting, or power conversion modules, thermal management is probably one of your biggest challenges. Thatâs where the double sided IMS PCB comes into play.
As a reliable IMS PCB manufacturer, Best Technology has been helping engineers and purchasing teams solve complex design issues using double sided metal core solutions that offer excellent thermal performance and mechanical strength. Our products are widely used in various applications like LED lighting, automotive electronics, power modules, and more.
What Is a Double Sided IMS PCB?
A double sided IMS PCB (Insulated Metal Substrate Printed Circuit Board) is a type of PCB that uses a metal baseâtypically aluminum or copperâcombined with two copper layers and insulating dielectric layers in between. This structure allows designers to place components on both sides or route critical signals more efficiently while managing heat effectively.
Unlike single-sided IMS PCBs that have components and traces only on one side, double-sided versions support components mounting and traces layout both on top and bottom side, it allowed complex designs, higher current flow, and better heat transfer through thermal vias.
In simple terms: if your board gets hot and needs more routing space, a double sided IMS PCB can help.
Double Sided IMS PCB Structure
A double sided IMS PCB is built with multiple carefully selected layers, designed to balance electrical performance, mechanical strength, and heat dissipation. The general structure looks like this:
Top copper layer: Carries the electrical traces and component pads.
Top dielectric layer: An electrically insulating but thermally conductive material.
Metal core: Usually aluminum or copper, it serves as a mechanical base and heat sink.
Bottom dielectric layer: Same material as the top layer, separating the metal core from the bottom copper.
Bottom copper layer: It is a trace layer, used for power, ground, or additional signal traces.
Plated through holes (vias) allow electrical connection between the top and bottom copper layers. These vias can also help conduct heat away from hot components into the metal core, improving thermal performance.
Types of IMS PCB Materials
In IMS PCB design, the metal base plays a critical role in heat dissipation and mechanical stability. The two most commonly used core materials are aluminum and copper, each with distinct advantages and application scenarios.
1. Aluminum-Based IMS PCB
Aluminum is by far the most widely used metal base material in IMS PCBs. It offers a great balance between cost, weight, and thermal performance. With a typical thermal conductivity of 1.0 to 3.0 W/m·K, aluminum is sufficient for most applications where moderate heat needs to be managed efficiently.
Advantages of aluminum base:
Cost-effective: More affordable than copper, suitable for mass production.
Lightweight: Ideal for weight-sensitive designs like automotive lighting and portable devices.
Corrosion-resistant: Naturally forms a protective oxide layer, extending board life.
Good thermal conductivity: Capable of dissipating heat from surface-mounted components quickly.
Typical applications:
LED lighting systems (e.g. street lights, home bulbs)
Power driver boards
Consumer electronics
Automotive LED modules
Aluminum IMS PCBs are perfect for designs that need reasonable thermal performance at a lower cost. They’re especially common in LED products, where keeping junction temperature low is essential to extending light source life.
2. Copper-Based IMS PCB
Copper-based IMS PCBs are chosen when thermal management becomes critical, or when mechanical robustness is equally important. Copper has a thermal conductivity of around 5.0 W/m·Kâmore than double that of aluminumâmaking it an ideal choice for high-power or high-density applications.
Advantages of copper base:
Superior heat dissipation: Excellent for fast heat transfer in high-power designs.
High mechanical strength: Less prone to flexing or warping under load or heat.
Stable performance at high temperatures: Supports continuous operation in demanding environments.
Better current carrying capacity: Enables narrower traces for the same current level.
Typical applications:
Power inverters and converters
Motor control units and industrial drives
RF amplifiers and telecom power modules
Aerospace and defense electronics
High-performance LED arrays
Due to its higher cost and weight, copper is generally used in specialized applications where reliability, thermal performance, or current handling are mission-critical. It’s especially favored in automotive power systems, high-end industrial equipment, and aerospace control circuits.
Single vs Double Sided IMS PCB
When choosing between single-sided and double-sided IMS PCBs, understanding their structural and functional differences is essential. Below is a detailed comparison covering performance, design flexibility, manufacturing complexity, and cost.
Comparison Aspect
Single Sided IMS PCB
Double Sided IMS PCB
Copper Layers
One layer on top
Two layers â top and bottom
Component Placement
Only on one side
Possible on both sides or top side with backside routing
Thermal Conductivity Path
Heat moves in one direction (top to base)
Heat can dissipate through both layers via thermal vias
Routing Flexibility
Limited routing options
More complex, denser routing possible
Via Usage
Usually no plated vias
Requires plated through vias for inter-layer connections
Design Complexity
Simpler, suitable for low-power applications
Supports more complex, high-current designs
Manufacturing Cost
Lower cost, fewer steps
Higher cost due to drilling, plating, and alignment
Board Thickness
Generally thinner
Slightly thicker due to multilayer structure
Current Carrying Capacity
Limited by single copper layer
Higher due to dual copper planes
Mechanical Strength
Moderate
Higher due to more balanced structure
Typical Applications
LED bulbs, indicator lights, basic power supplies
LED headlights, motor drivers, power inverters
Preferred Use Cases
Cost-sensitive and thermally moderate projects
Thermally demanding, high-power, or complex circuitry
At Best Technology, we provide both types with full engineering support, helping you select the right option based on your performance goals and budget.
IMS PCB Design Considerations
Designing an effective IMS PCB, especially a double sided IMS PCB, requires more than just basic layout knowledge. As a professional IMS PCB manufacturer, we often find that early-stage design decisions directly impact not only the cost but also manufacturability, reliability, and thermal performance.
Here are our top recommendations to help you design a high-quality IMS PCB that meets both technical and production requirements:
1. Understand the Thermal Path Early
IMS PCBs are often chosen for their excellent heat dissipation. To maximize this advantage:
Place heat-generating components (like LEDs, power ICs, MOSFETs) directly above the metal core or near thermal vias.
Use thermal reliefs for pads to balance solderability and heat transfer.
Avoid thick dielectric layers if fast heat conduction is criticalâchoose higher thermal conductivity materials instead.
2. Use Plated Vias Wisely
In double sided IMS PCBs, plated through holes (vias) are crucial to connect the top and bottom copper layers. However:
Vias increase cost due to drilling and plating steps.
Avoid placing too many vias near mechanical mounting holes to prevent cracking during assembly.
For high-current paths, increase via diameter and plating thickness, or use multiple thermal vias in parallel.
3. Optimize Trace Widths and Spacing
Due to higher currents in IMS boards:
Use wider traces wherever possible, especially for power lines.
Respect minimum clearance based on copper thickness and voltageâthis prevents arcing and improves reliability.
Avoid sharp 90° corners on high-current or RF traces; use 45° or curved corners instead.
If youâre not sure how wide your traces should be, send us your current ratingsâweâll recommend widths based on IPC standards and real-world performance.
4. Select Suitable Copper Thickness
For IMS PCBs, copper thickness directly impacts both electrical and thermal performance:
Standard thickness is 1oz (35”m), suitable for low to medium current.
For high current or improved thermal conduction, 2oz or 3oz copper is recommended.
Very thick copper (up to 10oz) is possible, but it increases cost and etching complexity.
5. Component Layout Planning
Avoid clustering hot components togetherâspread them out to help heat dissipation.
Keep temperature-sensitive components (like ICs, sensors) away from heat sources.
Leave clearance around mounting holes to prevent shorting with metal base.
6. Surface Finish Compatibility
Tell us your assembly process (manual, reflow, wave soldering) and component pitchâweâll advise the best finish.
ENIG is recommended for flat surfaces and fine-pitch components.
HASL is affordable but not ideal for tight layouts.
Immersion silver and OSP are good for high-frequency circuits.
7. Share Your Design Goals Early
Many designers only share Gerber files at the last step. But as a manufacturer, we can provide more value when weâre involved earlier.
Let us know if your priority is cost, thermal performance, space saving, or high current.
Share thermal simulation data if availableâwe can help validate materials and layout choices.
If youâre unsure between aluminum and copper base, we can guide based on your budget and operating temperature.
Contact us early often helps reduce revisions, avoid design traps, and improve yieldâsaving both time and money.
Double Sided IMS PCB Manufacturing Process
Manufacturing a double sided IMS PCB involves multiple controlled steps. Hereâs we simply introduce the manufacturing processed involving in the insulated metal substrate fabrication:
1. Material Lamination
The copper foils and dielectric are laminated on both sides of the metal base with high pressure and temperature.
2. Drilling & Via Formation
Mechanical or laser drilling creates via holes through the board. These holes are then plated with copper to allow connectivity between top and bottom copper layers.
3. Imaging & Etching
Circuit patterns are created on both copper layers using photoresist and chemical etching.
4. Solder Mask Application
Solder mask is applied to protect copper from oxidation and to guide solder placement during assembly.
5. Surface Finishing
Finish is applied on copper pads to enhance solderability and prevent corrosion.
6. Testing
Electrical tests (shorts/opens) and inspection ensure product quality before packaging and shipment.
Here is a completed manufacturing process of IMS PCB.
Double Sided IMS PCB Surface Finish Options
HASL (Lead-free): Affordable, but not ideal for fine-pitch components.
ENEPIG: Very good solderability, corrosion resistance, durable.
OSP: Cost-effective and environmentally friendly, but short shelf life.
Immersion Silver: Good for high-frequency signals, flat and solderable.
Hard Gold: Very durable, typically used for connectors or edge contacts, but rarely used in IMS PCB, it is popular in FR4 PCB.
At Best Technology, we recommend ENIG or ENEPIG for double sided IMS PCBs used in LED or power applications due to its durability and finish quality.
Cost Factors of Double Sided IMS PCB
The cost of a double sided IMS PCB is influenced by multiple variables, ranging from material selection to design complexity. As a manufacturer, we often find that many cost increases come from early design decisions. Here are the main cost drivers you should be aware of:
1. Material Type
Aluminum is more affordable and widely used, while copper offers better thermal performance but at a significantly higher price. If your project doesnât demand extreme thermal performance, aluminum is usually the better choice from a budget perspective. High Tg costs more.
2. Copper Weight
Thicker copper layers allow for higher current carrying capacity and better heat dissipation, but they also increase cost:
Standard: 1oz (35”m)
Mid-range: 2oz â 3oz
Heavy copper: 4oz â 10oz (used in power-intensive designs)
Heavier copper requires longer etching time and more material, which increases both processing time and price.
3. Board Size & Shape
Larger PCBs naturally use more material and occupy more space on the production panel. Irregular shapes also lead to more material waste and extra routing time.
Square or rectangular boards make better use of panel space.
Rounded or irregular outlines may require CNC routing or laser cutting, which adds cost.
4. Via Count and Type
Double sided IMS PCBs require plated through holes (PTH) to connect the two copper layers. The more vias you have, and the smaller their diameter, the more complex and expensive the drilling and plating process becomes. Via-in-pad, filled vias, and microvias are more expensive.
5. Dielectric Layer Thickness
Though not the focus here, itâs worth noting: if you select high-performance dielectric materials (e.g., with higher thermal conductivity or thinner thickness), the price will increase. These materials are more specialized and costlier to produce.
6. Special Features
Any additional processes will increase cost, such as:
Via-in-pad or filled vias
Selective plating or special coatings
Edge plating or beveling
Thermal simulations or FEA reports (optional support)
These are usually project-specific, so itâs best to clarify during the RFQ stage.
Best Technology â Your Reliable IMS PCB Manufacturer
When it comes to manufacturing double sided IMS PCBs, experience, precision, and consistency matter. At Best Technology, we specialize in high-performance metal core PCBs tailored to thermal management, power conversion, and LED lighting applications.
We offer:
Custom solutions using aluminum or copper base materials with various shapes
Precision-controlled dielectric thicknesses for consistent thermal resistance
Tight tolerance drilling and PTH plating for stable double-sided connections
Surface finishes like ENIG, ENEPIG, OSP, and lead-free HASL to match your assembly needs
Free DFM checks with technical support
24/7 before & after sales assist
Professional sales can provide best solution tailored to your specific requirement
Transparent price and data traceability
High quality control followed IATF 16949
No MOQ required, 1 pc available
Whether you need rapid prototypes or mass production, our engineering team supports you from design optimization to final testing. We believe that a good PCB starts with good communicationâand weâre always ready to listen.
To get an accurate and cost-effective quote, always provide the following details upfront:
Q1: What is the thermal conductivity of a double sided IMS PCB?
It depends on the dielectric used. Standard ranges are 1.0 to 3.0 W/m·K, with higher options available for demanding designs.
Q2: Can I place components on both sides of a double sided IMS PCB?
Typically, one side is reserved for power routing or heat dissipation, but yes, it’s technically possible depending on the application.
Q3: What surface finish is best for LED applications?
ENIG is recommended for its flatness, solderability, and long shelf life.
Q4: Are double sided IMS PCBs expensive?
They cost more than single-sided IMS or standard FR4 PCBs, but offer much better thermal and electrical performance, especially for power-intensive designs.
Q5: How can I get a quote from Best Technology?
Just email your Gerber files and requirements to sales@bestpcbs.com, and weâll respond within 24 hours.
How to choose MCPCB dielectric materialfor high-power LEDs? This guide covers material functions, types, selection criteria, and design best practices for high-power LED applications.
Are you worried about these issues?
LED temperature is too high, causing accelerated light decay?
Uneven thickness of insulation layer causes short circuit risk?
Is it difficult to control the cost of small batch orders?
Best Technology provide you with:
Free thermal analysis report:Dielectric layer thermal optimization plan is issued within 48 hours
Full process quality control: third-party test data is provided for each batch (including thermal conductivity/voltage resistance test)
Customized formula: adjust dielectric layer parameters according to power density (0.5-4.0W/m·K optional)
Welcome to contact us if you have any inquiry for MCPCB: sales@bestpcbs.com.
What Is MCPCB Dielectric Material?
MCPCB dielectric materialis a specialized insulating layer designed to efficiently conduct heat while maintaining electrical isolation between the circuit traces and the metal substrate (typically aluminum or copper) in metal-core printed circuit boards. Unlike traditional FR-4 laminates, this material exhibits significantly higher thermal conductivity (typically 1â3 W/m·K), making it essential for high-power electronic applications where heat dissipation is critical.
The material’s composition often includes epoxy-based resins filled with ceramic particles, which enhance thermal performance and mechanical stability. It must also withstand high operating temperatures (up to 140°C) and match the thermal expansion coefficients of the adjacent layers to prevent delamination.
What Are Functions of MCPCB Dielectric Materials?
Electrical Insulation: Prevents current leakage between conductive layers while allowing signal transmission.
Thermal Management: Transfers heat from components to metal core (typically aluminum/copper) with thermal conductivity up to 230 W/mK in advanced materials
Mechanical Support – Maintains structural integrity between metal base and circuit layers under thermal/mechanical stress.
Dielectric Stability – Maintains consistent dielectric constant (Dk) and low loss tangent (Df) across operating temperatures.
Process Compatibility – Withstands soldering temperatures (>288°C for lead-free processes) and laser drilling for via formation.
CTE Matching – Minimizes thermal expansion mismatch between layers to prevent delamination.
What Are Applications of MCPCB Dielectric Materials?
High-Quality Dielectric Material Solution – Provides a high-performance insulating layer with a thermal conductivity of 2.8W/m·K, which improves the heat dissipation efficiency by 40% compared to conventional materials.
24-Hour Rapid Prototyping Service – Accelerates product development cycle, reducing time-to-market by 30% compared to industry standards.
Fast Lead Times (7-15 days for bulk orders) â Shorten production cycles by 30% compared to competitors.
18+ Years Industry Expertise- Provides free DFM analysis to optimize designs for cost and performance.
Competitive Pricing with No Hidden Fees – Delivers 15â20% cost savings compared to European suppliers.
No-MOQ Flexibility â Start with small batches to test markets before scaling up.
Global Logistics Support â Hassle-free shipping to 50+ countries with customs expertise.
One-Stop Solution â From PCB design to assembly, reduce supplier management complexity.
24/7 Technical Support â Engineers on standby to resolve issues within 4 hours.
Long-Term Partnership Pricing â Volume discounts and flexible payment terms for repeat clients.
By integrating rapid response with professional technical services, we help customers achieve the core value of reducing R&D cycle by 50%+ and improving mass production yield to 99%, please feel free to contact Best Technology if you have any request for MCPCB: sales@bestpcbs.com.
What is IMS PCB technology? This guide covers its definition, benefits material options like aluminum substrates, applications, design rules, manufacturing processes, and future innovations.
Are you bothered by these problems?
Is your product frequently downtime due to insufficient heat dissipation?
Are you in a dilemma between material cost and heat dissipation performance?
Does space limitation limit your PCB design flexibility?
Best Technology can provide:
Our IMS PCB uses a high thermal conductivity aluminum substrate, which reduces thermal resistance by 50% to ensure continuous and stable operation.
Optimize the metal substrate process, reduce costs by 20%, increase heat dissipation efficiency by 30%, and achieve the best cost performance.
Support customized multi-layer metal substrates, compatible with high-density wiring, and adapt to compact space requirements.
Welcome to contact us if you have any request for IMS PCB: sales@bestpcbs.com.
What Is IMS PCB Technology?
IMS (Insulated Metal Substrate) PCB technologyintegrates a metal core, typically aluminum or copper with a thermally conductive dielectric layer and copper circuitry, creating a “metal-backed heat sink” for electronic components. Unlike traditional FR4 boards prone to overheating, IMS PCBs rapidly dissipate heat from high-power components (like LEDs, power converters, or 5G amplifiers), boosting device lifespan by up to 40% while preventing thermal failure. This makes them essential for demanding applications in automotive lighting, renewable energy systems, and medical devices, where efficient heat management ensures reliability, compact designs, and safety compliance.
What Are Advantages of IMS PCB Technology?
Benefits of IMS PCB Technology
Superior Heat Dissipation – Aluminum cores efficiently transfer heat away from high-power components (e.g., LEDs, power modules), reducing thermal stress and extending lifespan. Ideal for applications like automotive lighting and industrial power electronics.
Enhanced Durability – Metal substrates provide mechanical strength, resisting vibration and shockâcritical for rugged environments (e.g., aerospace, automotive).
Compact & Lightweight Design – Enables slimmer, lighter products without compromising performance, benefiting portable electronics and space-constrained systems.
High Electrical Insulation – Prevents short circuits even under high voltage, ensuring safety in power-sensitive applications.
Cost-Effective Longevity – Reduced cooling requirements (e.g., fewer heat sinks) lower overall system costs while improving reliability.
What Are Applications of IMS PCB Technology?
Applications of IMS PCB Technology
LED Lighting: High-power LED systems (e.g., streetlights, headlights) for heat dissipation and durability.
Automotive: Engine controls, EV battery management, and power modules for thermal/vibration resistance.
Power Electronics: Inverters, converters, and motor drives for compact, high-temperature performance.
Consumer Electronics: Adapters, chargers, and gaming devices to prevent overheating.
Industrial: Factory automation, robotics, and solar inverters for extreme-condition reliability.
What Are Substrate Material Types of IMS PCB?
Aluminum (AL) Substrates
Most common, cost-effective, and lightweight.
Thermal conductivity: 1â4 W/m·K (standard) to 10â15 W/m·K (premium grades).
Best for: LED lighting, power supplies, and automotive electronics.
Copper (Cu) Substrates
Higher thermal conductivity (up to 400 W/m·K).
More expensive but ideal for ultra-high-power applications (e.g., EV inverters, high-density power modules).
Steel Substrates
Lower cost, but heavier and less thermally conductive (â 1â2 W/m·K).
Used in: Industrial control boards where cost outweighs strict thermal needs.
Welcome to contact us if you have any request for IMS PCB: sales@bestpcbs.com.
Future IMS PCB Technology Trends
Advanced Thermal Materialsâ
Use of âhigh-thermal-conductivity ceramicsâ (e.g., AlN, BeO) for extreme heat dissipation.
Development of âflexible IMS substratesâ with better thermal performance.
Miniaturization & High-Density Interconnectsâ
Microviasâ and âHDI technologyâ for compact designs in automotive/5G applications.
Embedded componentsâ (resistors, capacitors) to reduce footprint.
Automotive & EV Focusâ
High-power IMS PCBsâ for âinverters, battery management, and motor drivesâ.
AEC-Q200 complianceâ for reliability in harsh environments.
Integration with AI & IoTâ
Smart PCBsâ with embedded sensors for real-time thermal monitoring.
AI-driven design optimizationâ for thermal efficiency.
Sustainable Manufacturingâ
Lead-free, halogen-free materialsâ to meet RoHS/REACH standards.
Recyclable metal coresâ (Al, Cu) for eco-friendly production.
High-Frequency & High-Speed Applicationsâ
Low-Dk dielectric materialsâ for 5G/mmWave RF applications.
EMI shielding integrationâ to minimize signal interference.
Conclusion IMS PCB technology delivers unmatched thermal performance (up to 12x better than FR4) and structural innovation (3-layer design), making it ideal for high-power LED, automotive, and industrial applications. With materials ranging from aluminum to hybrid substrates, the industry is advancing toward higher thermal conductivity (19W/mK+). Best Technology combines precision (±0.05mm tolerance) with rapid prototyping (24-hour turnaround) to provide reliable solutions. Contact our engineers today for a custom quote and expert support: sales@bestpcbs.com.
