Posts Tagged ‘copper core pcb’

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

Saturday, May 24th, 2025

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

Material Comparison: Copper vs Aluminum Core

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

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

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

Thermal Management: Which One Handles Heat Better?

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

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

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

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

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

Mechanical Strength and Weight: What Does Your Design Need?

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

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

Choose copper core PCBs if you need:

High mechanical stability
Vibration resistance
Long-term thermal durability

Choose aluminum PCBs if your product needs:

Lightweight design
Cost control
Simpler routing and drilling

Cost Consideration: Is Copper Always Worth It?

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

Aluminum PCBs are the better choice when:

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

Copper core PCBs are justified when:

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

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

Where to Use Each PCB Type?

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

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

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

5 Key Points Before You Choose

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

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

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

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

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

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

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

Why Choose Best Technology for Your Metal Core PCB?

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

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

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

FAQs

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

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

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

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

Q3: Do you offer hybrid metal core PCBs?

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

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

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

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

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

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

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

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

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

Conclusion

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

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

What Is a Copper Base PCB?

A Copper Base PCB is a type of metal core printed circuit board (MCPCB) that uses copper as the base material instead of the more common aluminum or FR4. This type of board is specifically designed to handle high heat, high power, and mechanical stress. The copper base acts as a heat sink, pulling heat away from components and distributing it more evenly. Compared with FR4 PCB, copper PCBs offer superior heat conductivity, mechanical strength, and current-carrying capacity.

Typical Structure of a Copper Base PCB

The structure of a copper base PCB is generally composed of three main layers, each playing a critical role in the board’s performance:

Copper Circuit Layer (Top Layer):

This layer contains the etched copper traces that form the electrical pathways. In copper base PCBs, this layer is often thicker than in standard PCBs—ranging from 1 oz to 20 oz or more—to handle higher current loads and improve heat distribution. These traces can be plated or coated depending on the application or customers requirements (e.g., ENIG, HASL, OSP).

Thermal Dielectric Layer (Middle Layer):

This is the insulating layer between the circuit and the metal base. It’s designed to have high thermal conductivity and excellent electrical insulation. Its main function is to transfer heat from the components to the copper base below while keeping the circuits electrically isolated. The thermal conductivity of this layer often ranges from 1 W/m·K to over 10 W/m·K, depending on material choice.

Copper Base Layer (Bottom Layer):

Unlike typical MCPCBs that use aluminum, this layer is made of solid copper—usually ranging from 1 mm to 3.5 mm thick or more. This acts as a heat sink, pulling heat away from the circuit layer and rapidly dispersing it. Copper’s thermal conductivity is about 400 W/m·K, significantly higher than aluminum (~200 W/m·K).

This design structure enables heat to be quickly conducted from the components to the copper baseplate, and then transferred through the heat sink or the casing, thereby enhancing the overall thermal management capability of the system.

What Are the Core Advantages of Copper Base PCBs?

Clients often wonder: “Why should I pay more for a copper base board?” Here’s why it might be worth it:

Exceptional thermal conductivity – Copper is far more effective at dissipating heat than aluminum or FR4, very suitable for high-wattage components.
High current tolerance – With thicker copper layers, these PCBs handle larger currents with minimal resistance.
Excellent mechanical durability – Copper PCBs are stronger and can withstand physical stress, vibration, and temperature cycling.
Improved electromagnetic shielding – Their dense base helps suppress EMI, a critical benefit in high-frequency applications.

These benefits result in longer product life, more consistent performance, and fewer field failures, especially in mission-critical applications.

Which Industries Benefit Most from Copper Base PCBs?

LED Lighting – High-power LEDs like COB, UV LED, floodlights, and grow lights require efficient thermal management.
Power Electronics – Power supplies, inverters, and converters benefit from copper’s high current-carrying capacity.
Automotive – EV batteries, headlights, and control systems need durability and consistent heat dissipation.
Telecom & RF Devices – Copper PCBs handle high frequencies with reduced signal loss and better EMI shielding.
Medical Equipment – High reliability is key for precision instruments that cannot afford overheating.

If your product involves heat, high power, or harsh environments, copper base PCBs are often the most dependable choice.

How Can You Tell If a Copper Base PCB Is Right for Your Project?

Before committing, ask yourself the following:

1. Does your design generate significant heat?

2. Is there limited space, but high power density?

3. Are you struggling with product reliability or failures due to overheating?

4. Is your end-product used in mission-critical or high-reliability environments?

If you answered “yes” to two or more of these, a copper base PCB could greatly improve your performance and reliability.

What Are the Limitations or Considerations of Copper Base PCBs?

While copper base PCBs offer outstanding thermal and electrical performance, they are not suitable for every project. Understanding their limitations and key design considerations is essential to avoid overdesign, unnecessary costs, or compatibility issues in your application.

1. Higher Material and Production Cost

Copper is significantly more expensive than aluminum or fiberglass (FR4). This cost factor affects both raw material pricing and manufacturing expenses. Additionally, the thicker copper layers and heavier base not only cost more to source, but they also require more energy and effort to process, increasing the total cost of production.

2. Heavier Board Weight

Copper has a high density (8.96 g/cm³ compared to aluminum’s 2.70 g/cm³), which means copper base PCBs are substantially heavier. This can present challenges in:

Weight-sensitive products such as drones or handheld devices
Shipping and logistics costs, especially for large quantities
Mechanical handling in assembly lines

Tip: If you’re designing a compact or mobile device, consider whether the weight trade-off justifies the thermal benefit.

3. More Challenging to Fabricate and Process

Due to the hardness and thickness of the copper base, special tooling, slower machining speeds, and experienced operators are required. Fabricators must use tougher drill bits, precise CNC machines, and advanced lamination processes to ensure:

Clean drill holes
Accurate etching and layering
Strong adhesion between layers

Poor processing can result in delamination, cracks, or electrical leakage—especially at the dielectric interface.

4. Limited Flexibility in Complex Layer Stack-Ups

While single-layer copper PCBs are common, multi-layer copper base PCBs are difficult and expensive to produce. This is because:

Each additional layer increases complexity in lamination
Heat must still flow effectively through the stack
Alignment and insulation tolerance become more critical

Not all manufacturers offer multi-layer copper PCBs due to the strict processing requirements and lower production yields.

5. Thermal Expansion and Stress Considerations

Copper has a relatively low coefficient of thermal expansion (CTE), which is good for dimensional stability. However, when paired with dielectric materials or mounted in assemblies with mismatched CTEs, thermal stress can build up during repeated heating and cooling cycles.

This can lead to:

Micro-cracking
Solder joint fatigue
Mechanical warping of the board

If you need help evaluating whether copper base PCBs are the right choice for your next project, Best Technology’s engineering team is here to offer thermal simulation, design review, and cost-performance optimization—so you only pay for what you truly need.

Why Choose Best Technology for Your Copper Base PCBs?

When it comes to copper base PCBs, expertise matters. At Best Technology, we provide end-to-end solutions — from thermal simulation and material selection to rapid prototyping and mass production.

Why choose us?

✅ One-on-one engineering support

✅ In-house thermal and mechanical design assistance

✅ Certified quality (ISO9001, ISO13485, IATF16949, AS9100D)

✅ MES system for full traceability

✅ On-time delivery and competitive pricing

Let us help you build reliable, high-performance PCBs tailored to your application needs.

Frequently Asked Questions (FAQs)

Q1: Is copper base PCB better than aluminum base for heat dissipation?

Yes, copper offers superior thermal conductivity compared to aluminum and handles higher thermal loads.

Q2: What thicknesses are available for copper base PCBs?

Copper thickness typically ranges from 1oz to 20oz or more depending on your current/thermal needs.

Q3: Can copper base PCBs support multi-layer structures?

Yes, although complex and costly, multi-layer copper base PCBs are feasible with the right process control.

Q4: How can I improve thermal performance in my copper PCB design?

Use thermal vias, select high-conductivity dielectric layers, and optimize component placement.

Q5: Why is copper base PCB more expensive?

Copper material, heavier base layers, and specialized manufacturing processes contribute to the higher cost.

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.