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Thick Copper PCB
Key Technical Features
- Current Carrying Capacity: Thicker copper reduces trace resistance, enabling higher current flow (e.g., 100A+ through 1mm-wide, 10 oz copper traces).
- Thermal Management: Improved heat dissipation via copper’s high thermal conductivity (401 W/m·K), ideal for power-dense components.
- Mechanical Rigidity: Enhanced structural strength for rugged environments (e.g., automotive vibration, industrial shocks).
Unmatched Electrical Performance
Low Resistance: Reduces power loss in high-current paths (e.g., 10 oz copper has 1/3 the resistance of 3 oz copper).
Stable Signal Integrity: Minimal voltage drop in power distribution networks, critical for automotive and industrial systems.
Superior Thermal Handling
Efficient Heat Dissipation: Copper layers act as heat sinks, preventing component overheating in power supplies and motor drives.
Thermal Cycle Resistance: Withstands repeated temperature fluctuations (-40°C to +125°C) without delamination.
Mechanical Durability
Heavy-Duty Construction: Reinforced through-hole plating and connector areas reduce mechanical stress failure.
Rugged Design: Suitable for harsh environments (e.g., military, aerospace, and heavy machinery).
Design Flexibility
Hybrid Layer Stacks: Combine thick copper power layers (e.g., 10 oz) with thin signal layers (e.g., 1 oz) for optimized performance.
Multi-Material Support: Available in FR-4, aluminum, ceramic (Al₂O₃/AlN), and flexible substrates.
Manufacturing Capabilities & Technical Specs
|
Feature |
Standard Capability |
Advanced Options |
|
Copper Thickness |
3–14 oz (inner/outer layers) |
15 oz (outer layer max) |
|
Layer Count |
1–24 layers |
Multilayer hybrid designs (power + signal) |
|
Material Options |
FR-4 (Tg 140°C/170°C), aluminum, ceramic, PTFE |
High-temperature materials (e.g., Rogers RT/duroid®) |
|
Trace Width/Spacing |
External: 9 mil/9 mil (4 oz) – 20 mil/32 mil (12 oz) |
Laser direct imaging for <5 mil precision |
|
Surface Finishes |
HASL (lead-free), ENIG, OSP, immersion silver |
Gold plating (hard gold for high-wear contacts) |
|
Thermal Management |
Thermal vias, copper infills |
Embedded heat sinks, liquid-cooling channels |
|
Testing |
Flying probe, AOI, Hi-Pot test |
Thermal impedance testing, X-ray inspection |
-
Electroplating
For layers up to 10 oz, using thick film copper cladding. -
Lamination
Bonding red copper foil (10–14 oz) with prepreg for ultra-thick layers. -
Solder Mask
Electrostatic spraying ensures uniform coverage on uneven copper surfaces.
Applications of Thick Copper PCBs
1. Automotive & EV/HEV
- High-Power Batteries: Battery management systems (BMS) with 8–12 oz copper for low-voltage, high-current paths.
- Motor Drives: Inverters and traction control modules requiring robust thermal dissipation.
- Ignition Systems: High-reliability PCBs for spark plug control in combustion engines.
2. Industrial Power Systems
- Power Supplies: 10–14 oz copper in switch-mode power supplies (SMPS) for data centers and renewable energy.
- Welding Equipment: PCBs withstand high transient currents and arc welding heat.
- Grid Infrastructure: Circuit breakers and overload relays with long-term thermal stability.
3. Aerospace & Defense
- Radar Systems: Heavy copper layers for high-power RF amplifiers.
- Military Vehicles: Rugged PCBs for weapons control and avionics, certified to MIL-PRF-55110.
- Satellite Power Modules: Ultra-thin (0.6mm) yet high-current designs for space applications.
4. Medical Equipment
- MRI/MRA Machines: Low-noise power distribution with 6–8 oz copper for electromagnetic compatibility (EMC).
- High-Power Lasers: PCBs for surgical equipment requiring precise thermal management.
Why Choose Our Thick Copper PCB Services?
Custom Design Support: Free DFM checks and copper thickness optimization to balance cost and performance.
Rapid Prototyping: 5–7 day turnaround for prototypes, the fastest in the industry for 10+ oz copper designs.
Mass Production Excellence: 7 Panasonic SMT lines ensuring 99.9% first-pass yield for assemblies.
Thermal Validation: Free thermal impedance testing for high-power designs.
Trusted by Global Leaders
Our solutions are used by clients in automotive (e.g., EV battery suppliers), industrial (e.g., solar inverter manufacturers), and medical sectors, with a proven track record in:
- High-Reliability Projects: PPAP Level 3 compliance for automotive clients.
- Extreme Environment Testing: Certified for vibration (MIL-STD-810G) and thermal shock (-40°C to +125°C).