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The 2025 Ultimate Guide to PCB Aluminium Substrate
Thursday, July 31st, 2025

PCB aluminium substrate is a go-to solution for high-performance electronics, especially where heat needs quick handling. It is widely used in LED lighting, automotive, and power devices due to its excellent heat conductivity and long-lasting structure.

Best Technology is a leading aluminum PCB board factory in China. Out of necessity, we have the sophisticated equipment in our factory, and we have invited lean agility to better process our customers’ prototypes and large orders as of late. If you have received the prototypes manufactured by us, you will see our advantage in PCB aluminium quality. Our engineering professionalism and relentless dedication to on-time delivery for our PCBs are plain to see in our actions. If you have any recent inquiries regarding the PCB aluminium substrate, we are pleased to respond with a great quote as rapid as we can. Just sent the specific files and details to us at sales@bestpcbs.com.
 

The 2025 Ultimate Guide to PCB Aluminium Substrate

What Is PCB Aluminium Substrate?

PCB aluminium substrate is a special type of printed circuit board that uses aluminium as its base material. This metal base helps in managing heat more effectively compared to standard materials like FR4. It supports better thermal flow, which is key in modern compact devices. This substrate usually includes three layers: the aluminium base, a dielectric layer for insulation, and a copper layer for the circuit.

What Is PCB Aluminium Substrate?

What Is the Difference: Aluminum PCB vs FR4?

Choosing between aluminium PCB and FR4 often depends on the application. Aluminum PCB vs FR4 mainly differs in heat management. FR4 is a common glass-reinforced epoxy material with low heat transfer. In contrast, aluminium PCB quickly removes heat from components. Aluminium boards also offer higher durability and support higher current loads. On the other hand, FR4 is more flexible for complex circuits but not suitable for high-power or high-temperature tasks.

FeatureAluminum PCBFR4 PCB
Base MaterialAluminum metalGlass-reinforced epoxy resin
Thermal ConductivityHigh (1.0–3.0 W/m·K)Low (0.25–0.3 W/m·K)
Heat DissipationExcellentPoor
Mechanical StrengthStrong and rigidModerate strength
Flexibility in DesignLimitedHigh (supports multilayer and flexible)
Current Carrying CapacityHighModerate
Cost per UnitHigher than FR4Lower than aluminum PCB
Typical ApplicationsLED lighting, power modules, automotiveConsumer electronics, communication
Temperature ResistanceHighLower
WeightHeavierLighter
DurabilityVery durableLess durable under high heat

What Is Aluminum PCB Dielectric Material?

The dielectric layer in an aluminium PCB is key for thermal transfer and electrical insulation. This layer sits between the aluminium base and the copper circuit. It is usually made from thermally conductive material, helping move heat away from the circuit. The quality and thickness of this layer affect both the performance and price of the board. At Best Technology, we use high-grade dielectric to ensure low thermal resistance and high reliability.

What Is the PCB Aluminium Substrate Price?

The PCB aluminium substrate price can vary based on factors like board size, copper thickness, and thermal needs. Basic aluminium boards for LEDs are quite affordable, while complex ones for power electronics cost more. Bulk orders often reduce the unit cost. At Best Technology, we offer competitive rates with added value from expert support and quality control.

How to Choose PCB Substrate Types?

Selecting PCB substrate types depends on your project needs. Consider heat levels, power load, size, and cost. If your design generates much heat or requires high strength, aluminium is ideal. For less heat and lower costs, FR4 might work. There are also ceramic and flexible substrates for special cases. Our engineers at Best Technology help customers pick the right substrate by reviewing their designs and offering practical advice.

CriteriaAluminum PCBFR4 PCBCeramic PCBFlexible PCB
Thermal ConductivityHighLowVery HighLow
Heat DissipationExcellentPoorExcellentPoor
Mechanical StrengthHighModerateHighFlexible (low rigidity)
Design FlexibilityLimitedHigh (multilayer possible)ModerateVery High
CostMedium to HighLowHighMedium
ApplicationsLED, power devices, automotiveConsumer electronics, general useHigh-frequency, medical, aerospaceWearables, compact devices
WeightHeavierLightModerateLight
DurabilityHigh (for harsh environments)ModerateVery HighLower (needs careful handling)

When to Use Aluminum Substrate PCB?

Use aluminum substrate pcb when thermal control is a priority. It’s perfect for LED lights, power supplies, automotive modules, and audio gear. These devices produce heat that needs quick removal to avoid failure. Aluminium boards help extend product life and ensure stable performance. They are also used in medical and military tools where dependability matters. In short, if heat affects your circuit’s life or performance, aluminium is worth considering.

Which Inspection Steps Are Included in the Aluminium PCB Production Process?

At Best Technology, every aluminium PCB manufacturing process follows strict inspection. The steps include:

  1. Incoming material checks – ensuring aluminium sheets meet quality standards.
  2. Copper circuit inspection – checking for cracks, shorts, or missing lines.
  3. Dielectric thickness check – measuring thermal insulation uniformity.
  4. Dimensional accuracy – verifying board size and hole placement.
  5. Thermal test – confirming heat transfer capability.
  6. Electrical test – verifying circuit continuity and insulation resistance.
  7. Final visual check – ensuring the finish is smooth and defects-free.

We also offer custom test setups based on your project’s needs, helping catch hidden issues before delivery.

Why Choose Best Technology for Manufacturing Aluminium PCB Board for LED?

Choosing the right manufacturer for aluminium PCB board for LED can solve many hidden challenges. Many customers face late deliveries, unclear communication, and inconsistent quality. Best Technology solves these with a professional engineering team, fast production lines, and strict quality control.

On-Time Delivery
Fast production lines help us ship your boards on schedule, avoiding project delays. Best Technology has an on-time delivery rate of 97%.

Clear Communication
Our team responds quickly and keeps you updated at every step. Our sales are not mere messengers; we grasp the full knowledge of the PCB aluminium substrate. You don’t need to keep waiting for a viable solution or answer after the sales confirm with the engineers.

Strict Quality Control

We help you optimize aluminum PCB design to improve heat transfer and reduce cost. We use high-grade materials and help fix design issues before production. In each manufacturing process, there are strict QC checks, followed by ISO 9001, ISO 13485, IATF 16949, AS9100D, UL, REACH, and RoHS standards.

Professional Engineering Support

Our engineers have valuable experience in offering custom solutions for different applications, from prototype to box build. If you want to do custom aluminium PCB sheet sizes, just find Best Technology.

To conclude, Best Technology values your time and goals, aiming for a smooth and worry-free experience. Any doubts or questions you would like to inquire, just let us know at sales@bestpcbs.com.
 

Why Choose Best Technology for Manufacturing Aluminium PCB Board for LED?

In a nutshell, PCB aluminium substrate is a smart choice for modern electronics, offering strong heat control and durability. It’s perfect for LEDs, power tools, and more. Knowing the differences between aluminium PCB and FR4, understanding dielectric materials, and learning about PCB aluminium substrate price helps in making better decisions. Choosing the right partner, like Best Technology, ensures your boards are reliable, cost-effective, and delivered on time. We help customers overcome typical issues in aluminium PCB manufacturing by offering quality materials, expert support, and fast lead times. A warm welcome to get a free DFM analysis and a particular quote from us. Just share your Gerber Files, the detailed requirements, and the order quantity with us at sales@bestpcbs.com.
 

PCB Aluminium Substrate, Aluminum PCB Board for LED
Thursday, April 17th, 2025

When it comes to reliable and advanced PCB solutions, Best Technology leads the way. With more than 18 years in the industry, we provide custom circuit board manufacturing for global clients. From prototype to volume production, we help you build better products with very good heat dissipation and military-grade quality. Our strength lies in metal-based PCBs, especially pcb aluminium substrates. These are widely used in LED, automotive, telecom, and power industries. With precision equipment and a strict quality system, we ensure high-performance boards that meet your needs.

What Is a PCB Aluminium Substrate?

A PCB aluminium substrate is a type of metal-based printed circuit board. (MCPCB) It uses aluminum as its base material instead of traditional FR4. This base supports layers of dielectric, and copper circuits. Aluminum PCBs offer strong heat dissipation and structural support compared with normal rigid PCB. The aluminum base acts as a heat sink. This makes the substrate ideal for high-power or thermally sensitive applications. In simple terms, it’s a PCB built on aluminum rather than fiberglass.

Performance of Aluminium Substrate PCB in LED

Aluminum substrate PCBs are the backbone of today’s LED lighting systems. Their ability to manage heat is the most critical factor. When LEDs operate, they generate a lot of heat at the junction point. If that heat isn’t removed quickly, the LED’s brightness fades, and its lifespan shortens. Using an aluminum board for LED, we can get these benefits:

  • Efficient heat dissipation: The aluminum metal base acts as a built-in heat sink, pulling heat away from the LED source and spreading it across the board.
  • Improved reliability: By reducing thermal stress, the board helps extend the lifespan of each LED component. That means longer-lasting light and less need for replacement.
  • Stable light output: Overheating causes LEDs to dim. Aluminum PCBs maintain the thermal balance so that brightness stays consistent. Whether it’s a street lamp or a small indoor fixture, aluminum PCBs deliver stable operation.
  • Compact design: Since aluminum boards manage heat on their own, there’s no need for bulky external cooling systems.
  • Cost-effective: Although slightly more expensive than FR4, their longer lifespan and lower maintenance needs make them a better investment for lighting manufacturers.

6061 vs. 5052 vs. 1060 Aluminum Substrate

In the aluminum PCB manufacturing, the common aluminium substrates that manufacturers always use are 6061 aluminum substrate, 5052 aluminum substrate and 1060 substrate. All of them are aluminum allay, but the compositions and purity are different, so that the performance different too.

5052 aluminum sheet belongs to Al-Mg alloy, the main alloying element is magnesium, which has a content of 2.2% ~ 2.8%. In addition, it also contains a small amount of chromium (0.15%-0.35%) and other elements. The addition of which is intended to improve the strength and corrosion resistance of the alloy. 6061 aluminum sheet is Al-Mg-Si alloy, in addition to magnesium (0.8%-1.2%) and silicon (0.4%-0.8%) as the main alloying elements, copper (0.15%-0.4%) and zinc (less than 0.25%) are also added. 1060 aluminum material belongs to pure aluminum sheet, with an aluminum content of more than 99.6%, and almost no other alloying elements. Different alloy components form the basis of the different performances of these aluminum substrates. Below is a table comparison show the differences between each of them:

Property6061 Aluminum5052 Aluminum1060 Aluminum
CompositionMagnesium & silicon alloyMagnesium alloyPure aluminum (≄99.6%)
Thermal ConductivityModerate (150 W/m·K)High (160 W/m·K)Very high (≈237 W/m·K)
Strength of Extension290MPa215MPaLow
Hardness95HB65HB30HB
Elongation10-18%12-25%5%
FormabilityLowHighHigh
Corrosion ResistanceGoodExcellentGood
Common UsesStructural parts, high-load PCBsLED lights, flexible designsHigh heat-dissipation PCBs
CostHigherMediumLower
(6061 vs. 5052 vs. 1060 Aluminum Substrate)

So how to choose the suitable substrate for your aluminum PCB board? Follow this rule:

  • Choose 1060 if your project needs maximum thermal conductivity.
  • Choose 5052 if flexibility and corrosion resistance are more important.
  • Choose 6061 if you need strength and rigidity for heavy-duty PCBs.

What Is the Dielectric Layer of Aluminum PCB?

Aluminum substrate is generally composed of three layers: circuit layer (copper foil), dielectric layer and metal base. The dielectric layer is located between the circuit layer and the metal base layer, which acts as insulation and heat conduction. It is a polymer filled with high thermal conductivity and high insulation ceramic powder, make it is an ideal material with non-conductive but heat-conductive.

single sided PCB aluminium substrate structure

This dielectric layer has good heat conduction properties (thermal conductivity up to 3.0W/m-K), it is the key to thermal performance. It allows heat to pass from the copper to the aluminum while keeping them electrically isolated. The dielectric must have low thermal resistance and high breakdown voltage. Materials used often include ceramic-filled epoxy or polyimide. These support thermal conductivity while maintaining safety.

What Is the Difference Between FR4 and Aluminum PCB?

FR4 PCBs use fiberglass as a base. They are cheaper and more common. But they are poor at dissipating heat. They also deform more under thermal stress. Aluminum PCBs, on the other hand, handle heat much better. The aluminum pcb thermal conductivity is usually between 1.0 to 3.0 W/m·K. In contrast, FR4 is less than 0.3 W/m·K. That means aluminum PCBs can move heat away much faster. Here we listing the main differences between two of them:

FeatureFR4 PCBAluminum PCB
Base MaterialFiberglass-reinforced epoxyAluminum metal
Thermal Conductivity≈0.3 W/m·K1–3 W/m·K
Heat DissipationPoorExcellent
Mechanical StrengthModerateHigh
EMI ShieldingWeakStrong
Cost (under the same design complexity situation)LowerSlightly higher
Use CasesConsumer electronics, PCsMainly used in led lights, automotive, power modules
Thickness Options0.10mm, 0.12mm, 0.15mm, 0.20mm, 0.25mm, 0.30mm, 0.40mm, 0.50mm, 0.60mm, 0.80mm, 1.0 mm, 1.2 mm,  1.6mm, >=2.0 mm0.30mm, 0.40mm, 0.50mm, 0.60mm, 0.80mm, 1.0 mm, 1.2 mm, 1.6mm, 2.0 mm, 2.4mm, 3.0mm (exclude copper)
WeightMuch lighterHeavier but lighter than copper pcb
Environment ToleranceLower heat resistanceWithstands high temperatures

How Do You Make Aluminium PCB?

The manufacturing process of aluminum PCB is almost the same as normal FR4 PCB, except the lamination process of dielectric layer, aluminum and copper. This also is the biggest manufacturing difficult that faced by manufacturers, especially for multi-layer aluminum PCB. For the single & double sided aluminum PCB, the aluminum substrate we purchased from the manufacturers are laminated with dielectric, so we do not need to laminate again. In addition to this, the manufacturing process of aluminum PCB with insulated hole and without insulated hole are different.

  • Single-sided Aluminum PCB without insulated hole:

Cutting raw material (substrate laminated with dielectric layer) — Circuit layer generation (D-E-S) — Solder Mask – Silkscreen — Surface Treatment — Stripping — Drill Holes — Outline (V-cut – Routing – Die Punching) — QC — Package & Delivery

Single-sided Aluminum PCB without insulated hole
  • Single-sided Aluminum PCB with insulated hole:

Cutting raw material (substrate without laminated with dielectric layer) — Drill larger holes — Filled resin with holes — Lamination (dielectric layer + copper + aluminum base) — Circuit layer generation (D-E-S) — Solder Mask – Silkscreen — Surface Treatment — Stripping — Drill Holes — Outline (V-cut – Routing – Die Punching) — QC — Package & Delivery

Single-sided Aluminum PCB with insulated hole

Manufacturing Difficulties of Aluminum PCBs

Working with aluminum is not the same as working with FR4. It brings challenges, especially for a professional aluminum PCB manufacturer.

1. Mechanical Processing

Drilling holes on aluminum PCBs is possible, but the inner walls and board edges must be completely free of burrs. Even a slight burr can cause the board to fail the high-voltage test. Milling the outline is also quite difficult. The milling cutter used for FR4 PCB board has a relatively low hardness, while the milling cutter used for aluminum substrate has a high hardness. During the processing, the milling cutter for fiberglass board production has a high speed, while the milling cutter for aluminum substrate production has a speed at least 2/3 slower. As an alternative, punching with high-precision dies is often used—but die making requires exceptional skill, making this one of the main challenges in aluminum PCB manufacturing.

After punching, the edges must be clean and smooth, without any burrs or damage to the solder mask along the edges. Most factories use compound dies. Holes are punched from the circuit side, and the outline is punched from the aluminum side. This requires specific techniques, such as upward shearing and downward pulling during punching. Even after punching, the board’s warpage must be strictly controlled and should remain under 0.5%.

2. Protecting the Aluminum Surface During Processing

The aluminum base must remain completely free of scratches throughout the entire production process. Any direct contact with hands or chemicals can cause surface discoloration or oxidation, which are absolutely unacceptable. In many cases, re-polishing the aluminum surface is not allowed by customers. So, avoiding even the slightest damage to the aluminum layer is another major difficulty in the production process.

Some manufacturers use surface passivation treatments, while others apply protective films before and after hot air solder leveling (HASL). There are countless tricks and methods used to keep the surface clean—every factory has its own unique way of doing it.

3. High-Voltage Testing Requirements

For telecom power supply boards, 100% high-voltage testing is often mandatory. Some clients require DC testing, while others specify AC, typically at 1500V or 1600V for durations of 5 to 10 seconds. Every single board must pass this test.

Even the smallest contamination on the surface, burrs on holes or edges, jagged traces, or damage to the insulation layer can lead to arcing, leakage, or dielectric breakdown during testing. Boards that show signs of delamination or bubbling during the test are automatically rejected.

Despite these, trusted manufacturers like Best Technology handle it well. Our experience helps solve such problems early in the process.

How Much Does Aluminum PCB Cost?

Many factors influence the pcb aluminium substrate price. These include:

  • Aluminum grade (6061, 5052, or 1060)
  • Thickness of copper and base layer
  • Board size and layer count
  • Surface finish type
  • Quantity ordered
  • Special design features (e.g., thermal vias, contours)

In general, aluminum PCBs cost more than FR4 boards. But for heat-sensitive designs, the added cost pays off in reliability.

For instance, a basic one-layer aluminum PCB may start from $1.0–$5.0 per unit in bulk. Complex designs with multi-layers or special finishes can go higher. Best Technology offer competitive pricing without cutting corners. We also provide quick prototypes aluminium PCB substrate and full-scale production to meet your timeline and budget.

If you are interested in PCB aluminium substrate or aluminum PCB manufacturing, contact us today to learn more about our aluminum PCB board solutions. Let’s build something great together—strong, reliable, and ready for tomorrow’s tech.