Posts Tagged ‘copper metal core pcb’

Copper Metal Core PCB Design Guide & Thermal Solution

Friday, August 1st, 2025

Looking for copper metal core PCB thermal solution? Let’s explore spec, benefits, application, design guide and thermal solution, manufacturing process for copper metal core PCB.

Are you worried about these problems?

Is your LED product experiencing luminous efficacy degradation due to insufficient heat dissipation?
How can you avoid reliability risks when high-power devices experience uncontrolled temperature rise?
Struggling to balance cost and performance? How can you choose a lightweight solution?

Best Technology can provide solutions

Precise Thermal Matching Service: Through thermal simulation modeling, we customize the copper layer thickness (available in 0.1-3.0mm), ensuring a 40% reduction in LED module junction temperature and a 50% reduction in lumen degradation.
High-Current Wiring Technology: Utilizing an immersion gold (Immersion Gold) + OSP process, it supports a continuous current of 5A/mm², eliminating overheating issues in power modules and increasing yield to 99.2%.
Lightweight Structural Design: Copper foil micro-etching technology achieves 50μm line/space widths. A multi-layer stacking solution reduces drone battery pack size by 20% and extends flight time by 15%.

Welcome to contact us if you have any request for metal core PCB: sales@bestpcbs.com.

What Is Copper Metal Core PCB?

A Copper Metal Core PCB (Printed Circuit Board) is a type of circuit board that uses copper as the base material instead of the traditional fiberglass (FR4). This metal core is typically located beneath the circuit layer and serves as a thermal conductor to dissipate heat generated by electronic components during operation. Copper metal core PCB has superior thermal conductivity, making it highly effective for managing heat in power electronics, LED lighting, automotive systems, and industrial control equipment.

Copper Metal Core PCB Specification

Parameter	Specification
Base Material	Copper (typically C1100 or similar high-purity copper)
Copper Core Thickness	0.5 mm, 1.0 mm, 1.5 mm, 2.0 mm, up to 5.0 mm (custom thickness available)
Circuit Layer Copper Thickness	1 oz, 2 oz, 3 oz, up to 10 oz (35 µm to 350 µm)
Dielectric Layer Thickness	0.05 mm to 0.5 mm
Thermal Conductivity of Dielectric	1.0 W/m·K to 5.0 W/m·K or higher
Thermal Conductivity of Copper Core	~400 W/m·K (excellent thermal performance)
Operating Temperature Range	-40°C to +150°C or higher depending on design
Surface Finish Options	HASL, ENIG (Electroless Nickel Immersion Gold), OSP, Immersion Tin/Silver
Solder Mask Color	Green, White, Black (custom colors available)
Board Size	Up to 600 mm × 1200 mm (larger sizes possible upon request)
Drilling Options	Mechanical drilling, laser drilling for micro vias
Layer Count	Single-sided, double-sided, multilayer (up to 4 layers typical)
Impedance Control	Available for RF/high-frequency applications
Certification Standards	ISO9001, UL, RoHS, IPC Class 2/3 compliant

Benefits of Copper Substrate PCB

Exceptional Heat Dissipation: Copper’s high thermal conductivity (2x aluminum) rapidly transfers heat away from components, preventing overheating in LEDs, power modules, or automotive systems.
Longer Device Lifespan: Reduces thermal stress and component failure, extending reliability for high-current applications like EV chargers or industrial equipment.
Compact Design Flexibility: Thick copper layers enable dense circuits and smaller boards, saving space in 5G devices, RF systems, or medical electronics.
Cost-Effective Performance: Minimizes need for external cooling parts (fans/heatsinks), lowering long-term maintenance and material costs.
Versatile Application Fit: Ideal for high-power (solar inverters), precision (aerospace), and EMI-sensitive (radar) designs, ensuring stable operation in extreme environments.

Applications of Copper Metal Core PCBs

High-Power LED Lighting: Efficiently dissipates heat from dense LED arrays, preventing color shift and extending lifespan for automotive, industrial, and architectural lighting.
Automotive Electronics: Manages heat in power modules (e.g., engine control units, battery management systems) under extreme temperatures, enhancing reliability for EVs and hybrid vehicles.
5G & RF Devices: Supports high-frequency circuits and millimeter-wave components by minimizing thermal noise, critical for 5G base stations and radar systems.
Industrial Power Systems: Withstands high currents and thermal stress in motor drives, inverters, and solar power converters, reducing downtime and maintenance costs.
Aerospace & Defense: Provides lightweight, durable thermal management for avionics, satellite components, and ruggedized communication gear in harsh environments.

Copper Metal Core PCB Design Guide

Below is copper metal core PCB design guide:

1. Material & Substrate Selection

Use copper-core substrates (thermal conductivity ≥2W/mK) or ceramic substrates (AlN, 320W/mK). Avoid FR4.
High-power areas: 3-4oz copper; peripheral zones: 2oz. Transition zones use teardrop shapes (≤45°).
Ensure lead-free solder (SAC alloy), halogen-free laminate, and RoHS/REACH compliance.

2. Thermal Management

Spread high-power components (e.g., power ICs) to prevent heat buildup. Place heat-generating parts on outer layers for direct cooling.
Thermal vias: 0.3mm diameter, ≥4 vias/cm², 30μm copper plating. For IGBTs, embed 1.5mm heat pipes (local temp rise ≤15°C).
Add 10μm graphene film on copper layers to boost thermal diffusion by 40%. Validate designs with ANSYS/Flotherm and IR thermography.

3. Stack-Up & Board Thickness

For RF circuits, use Rogers RO4000 (Dk=3.38). Multi-layer boards: 6 layers reduce crosstalk by 60-70% vs. 4 layers. Apply 20H rule (power plane indented 20× layer spacing).
Standard thickness: 1.6mm; use ≥2.0mm for high-power applications.
Maintain >85% copper uniformity. Blind/buried vias reduce thermal stress by 30%.

4. Routing & Signal Integrity

Track width: 1mm (1oz copper) = 1A. Widen tracks for high current (1A/0.3mm). Prioritize power traces to minimize impedance.
High-speed signals: 3W spacing, matched lengths, 135° bends. Crystal circuits: Ground enclosure with stitching vias.
Route critical signals (e.g., clocks) first. Bridge splits with 0.1μF + 10μF capacitors.

5. Vias & Solder Mask

Laser vias: ≥0.1mm; mechanical vias: ≥0.2mm. Tolerance ±0.05mm (≤0.8mm vias). High-speed vias: Stub length <10mil; back-drill tolerance ±2mil.
Solder mask: Expand 0.05-0.1mm beyond pads. For BGAs, use NSMD (mask opening 15-25μm larger than pad). Remove mask in thermal zones.

6. Manufacturing & Testing

Hole aspect ratio (diameter:total thickness) ≤10:1. Metal-base tolerance: ±0.1mm; add 0.3mm vent holes per 20×20mm.
Reliability tests: Environmental: Thermal cycle (-40°C/+125°C), 95%RH/40°C/96h. Mechanical: Tensile strength >10N; peel strength ≥1.0N/mm.
Electrical: Contact resistance (mΩ-Ω range); insulation >10⁷Ω; HiPot.

7. Special Applications

High-power modules: Step-down copper (4oz core, 2oz periphery); embed AlN or heat pipes.
Flex designs: Rigid-flex follows rigid rules; keep 1.5-2mm clearance from SMD outlines.
Low-temperature: Use high-Tg substrate (Tg>170°C); increase via density.

Copper Metal Core PCB Thermal Solution

1. Advanced Thermal Materials

Graphene-Enhanced Copper: Utilize copper-graphene composites (thermal conductivity up to 440W/mK) for core heating zones. Apply 10μm graphene films on copper layers to boost lateral thermal diffusion by 40%.
Staged Copper Thickness: Use 4oz copper for high-power areas (e.g., IGBTs), transitioning to 2oz in peripheral zones via teardrop-shaped (≤45°) connections.

2. Via Array Optimization

Thermal Vias: Deploy 0.3mm diameter vias in hotspots (density ≥4 vias/cm²), reducing thermal resistance by 90% compared to non-via designs.
Dynamic Spacing: Use hexagonal via patterns for heat flux >50W/cm²; rectangular arrays for <30W/cm². Maintain via spacing ≥2×via diameter +0.1mm.
Copper-Via Synergy: Thicken via walls to ≥30μm when outer-layer copper exceeds 35μm. Reduce via spacing to 0.8mm for 35μm copper layers.

3. Heat Pipe Integration

Embedded Heat Pipes: Insert 1.5mm-diameter heat pipes beneath IGBTs, filled with phase-change material. Limits local temperature rise to ≤15°C (5× more efficient than vias alone).
Patent-Proven Designs: Fix heat pipes to aluminum substrates via high-temperature soldering, ensuring direct contact with chassis for efficient heat dissipation.

4. Thermal Path Engineering

Vertical-Horizontal Hybrid Cooling: Combine 0.3mm vias (vertical heat transfer) with 0.5mm linewidth hexagonal grids (horizontal spreading) in non-critical zones.
Ceramic Insertion: Embed AlN ceramic pads (thermal conductivity 320W/mK) under power modules, bonded with silver paste to achieve baseplate thermal resistance <0.15°C/W.

5. Simulation & Validation

Thermal Modeling: Use ANSYS Icepak with 3× denser mesh in via regions. Validate against real-world data (e.g., 48V DC/DC module via optimization reduced thermal resistance from 1.2°C/W to 0.78°C/W).
Infrared Testing: Confirm design efficacy via thermal imaging, ensuring peak junction temperatures stay below 125°C (with <10°C rise per 10% power increase).

6. Manufacturing Adjustments

Aspect Ratio Control: Maintain via diameter-to-board thickness ratio ≤10:1. Tolerance: ±0.05mm for vias ≤0.8mm.
Solder Mask Management: Expand solder mask 0.1mm beyond pads; remove mask entirely in thermal via arrays to enhance heat dissipation.

How to Make A Copper Metal Core PCB?

1. Material Preparation

Substrate Selection: Choose copper-core substrates (thermal conductivity ≥2W/mK) or ceramic substrates (AlN, 320W/mK). Avoid FR4.
Copper Foil: Use 3-4oz copper for high-power areas; 2oz for signal layers. Pre-treat copper surfaces for adhesion.
Auxiliary Materials: Prepare dry film, solder mask ink, and semi-cured sheets (PP) for lamination.

2. Inner Layer Fabrication

Surface Cleaning: Clean substrates to remove oils, oxides, and contaminants.
Dry Film Application: Lamination of photosensitive dry film on copper surfaces.
Exposure & Development: UV exposure transfers circuit patterns to the dry film. Unexposed areas are dissolved in developer solutions.
Etching: Remove unprotected copper using alkaline etchants (e.g., ammonium persulfate).
AOI Inspection: Automatic Optical Inspection (AOI) detects defects like opens/shorts.

3. Lamination

Stack-Up: Align inner layers, PP sheets, and outer copper foils per design. Use pins/optical alignment for precision.
Pressing: Apply heat (180–220°C) and pressure (1.5–2.5MPa) to melt PP and bond layers. Maintain vacuum to eliminate air bubbles.
Post-Press Treatment: Cool boards gradually to avoid warping. Trim edges and remove excess PP.

4. Drilling & Plating

Mechanical/Laser Drilling: Drill through-holes, blind/buried vias. Laser drilling is used for microvias (<0.15mm).
Deburring: Remove drill swarf and smooth hole walls.
PTH (Plated Through-Hole):
Desmearing: Clean hole walls with plasma/permanganate.
Chemical Deposition: Coat holes with a thin copper layer (1–2μm).
Electroplating: Thicken copper to 20–40μm for conductivity and durability.

5. Outer Layer Fabrication

Dry Film Application: Repeat processes for outer layers.
Exposure/Development/Etching: Similar to inner layers but with tighter tolerances.
Tin Plating (Optional): Electroplate tin as an etch resist for selective copper retention.

6. Solder Mask & Silkscreen

Solder Mask Application: Coat boards with liquid photoimageable solder mask (LPI).
Exposure/Development: Expose mask to UV light, leaving pad areas uncovered.
Curing: Bake boards to harden the mask.
Silkscreen Printing: Add component labels, logos, and markings using UV-curable ink.

7. Surface Finish

HASL (Hot Air Solder Leveling): Dip boards in molten solder, then level with hot air. Cost-effective for general use.
ENIG (Electroless Nickel/Immersion Gold): Deposit nickel (3–5μm) and gold (0.05–0.1μm) for flat surfaces and corrosion resistance.
OSP (Organic Solderability Preservative): Apply a thin organic layer for lead-free compatibility.

8. Routing & Testing

CNC Routing: Cut boards to final dimensions using milling machines. Add V-scores for easy breaking.
Electrical Testing:
Flying Probe: Check for opens/shorts with movable probes.
Fixture Test: Use bed-of-nails for high-volume inspection.
Final Inspection: Visual check for defects (e.g., solder mask bridges, misalignment).

9. Packaging & Shipping

Vacuum Packing: Seal boards in anti-static bags with desiccants.
Labeling: Include PCB specs, date codes, and compliance marks (RoHS, UL).

Why Choose Best Technology as Metal Core PCB Manufacturer?

Global ISO/RoHS/REACH/UL Compliance: One-step certification for EU/US markets.
Free DFM Support: Avoid costly redesigns with first-pass success guarantee.
1 Piece MOQ & 24-Hour Rapid Prototyping: Accelerate product validation by 5x, beat competitors to market.
A Week Mass Production Turnaround: Eliminate supply chain bottlenecks during peak seasons.
Thermal Performance Optimization: Reduce power module temperatures by 25%, extend product lifespan.
Strict Quality Inspection: Conduct full inspection in batches and strictly control quality to reduce the cost of rework for customers.
Competitive Price: Transparent Price Structure, No hidden Cost to be incurred.
Cost-Efficient Material Solutions: Achieve 15% higher profitability for LED/5G products.
High-Density Routing Expertise: Miniaturize IoT devices without sacrificing performance.

Welcome to contact us if you have any request for metal core PCB: sales@bestpcbs.com. Looking forward to hearing from you soon!

Tags:copper metal core pcb, Metal Core PCB
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Copper Metal Core PCB, Copper Core PCB Factories & Manufacturer

Thursday, April 24th, 2025

Copper Core Metal Core PCB Definition

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

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

Copper Metal Core PCB, Copper Core PCB Factories & Manufacturer

Copper Core PCB Structure

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

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

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

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

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

Types of Copper Core PCB

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

Normal Copper Core PCB

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

SinkPad Copper-Based PCB

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

Sinkpad copper-based pcb stack up:

Features of Copper Core PCB

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

Copper Metal Core PCB Design Guidelines

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

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

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

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

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

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

Copper Metal Core PCB Applications

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

How to Choose Copper Core PCB Factories?

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

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

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

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

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

1. Adwin Circuits

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

2. PCBgogo

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

3. Millennium Circuits Limited (MCL)

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

4. Best Technology

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

5. PCBWay

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

6. Sierra Circuits

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

7. JLCPCB

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

8. FX PCB

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

9. PCBONLINE

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

10. Leiton GmbH

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

Why Choose Best Technology as Your Copper Core PCB Supplier?

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

Copper Metal Core PCB Prototype

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

Copper Metal Core PCB Assembly

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

FAQs

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

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

2. Can copper core PCBs support multilayer designs?

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

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

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

4. Are copper metal core PCBs expensive?

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

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

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

Tags:Copper core pcb factories, Copper core pcb manufacturer, copper metal core pcb
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