PCB copper layers that are thicker than 1 oz. copper are used in certain high-power applications such as automotive, Industrial Controls, aerospace, and more. This helps improve handling of high currents, heat dissipation, and durability. These specialized PCBs are known as heavy copper PCBs which have copper weights ranging between 4 oz. and 20 oz. At PCB YOU, we manufacture robust and reliable heavy copper PCBs and offer turnkey assembly services based on your requirements. Our heavy copper PCBs are designed to withstand the toughest operational environments and enhance thermal management and conductivity across applications from industrial controls to automotive systems, ensuring that your products perform effectively.
Our Heavy Copper PCB Capabilities
PCB YOU has the capability to make heavy copper PCBs in the following specifications.
- We use standard as well as high Tg FR4 boards, which means the glass transition temperature (Tg) ranges between 140 degrees to 180 degrees Celsius.
- Spacing of trace layers is important for internal as well as external layers. For internal layers, we offer a minimum spacing of 4oz Cu 8mil/12mil, 5oz Cu 10mil/14mil, 6oz Cu 12mil/16mil, or 12oz Cu 20mil/32mil. For external layers, we allow a minimum spacing of 4oz Cu 9mil/9mil, 5oz Cu 11mil/11mil, 6oz Cu 13mil/13mil, 12oz Cu 20mil/32mil.
- We keep a minimum hole size of 10 mil with the board thickness ranging between 0.6 and 6 mm.
- Our options for surface finishing include lead free HASL, immersion gold, OSP, Hard Gold, Immersion Silver, and ENEPIG.
- The maximum copper weight we offer for inner layer is 12 oz, and 15oz for finished outer layer.
- We use a variety of colors for silkscreen as well as solder mask. Such as green, red, yellow, blue, white, black, purple, matte black, matte green, and matte red.
- We use advanced via processes to create via in pad, blind and buried vias, tenting, and plugged vias.
- We do testing and inspection at each stage using advanced methods such as automated optical inspection (AOI), fly probe testing, and more.
Benefits of Heavy Copper PCBs in High-Power Applications
Some PCBs have higher traces to carry higher current levels (amperage). However, thicker copper is required to transfer signals across the board as power requirements increase. Heavy copper PCBs are utilized in high current designs for this reason.
- Heavy copper PCBs can withstand greater currents without overheating because of their thicker copper layers, which is crucial for ensuring secure and reliable operation even under heavy electrical loads.
- These PCBs offer exceptional mechanical strength, which enables them to resist heat cycling, vibration, and shock. Hence, these assemblies find application in industrial machinery, aviation, automotive, and military sectors.
- Thick copper PCBs provide superior heat dissipation, dispersing heat uniformly and shielding delicate components, leading to enhanced thermal management. This benefits the device in terms of efficiency and reliability, and prevents overheating.
- With the ability to support high current channels and high-density interconnections in single-sided, double-sided, or multilayer arrangements, heavy copper printed circuit boards (PCBs) enable complex and compact designs. This flexibility is particularly useful in high-performance, space-constrained applications as it streamlines the overall design and minimizes the need for extra components.
Why Choose PCB YOU for Heavy Copper PCBs
Heavy copper PCBs can fail if not designed properly. At PCB YOU, we take care of the minutest details right at the design stage. Hence, we are absolutely reliable partners for your requirements involving heavy copper PCBs. Here are some pointers.
- In heavy copper PCB assemblies, there may be issues pertaining to deformation, warping or uneven surface finishes, delamination, shorting possibilities, and more due to copper thickness. We eliminate all these issues at the PCB design level by creating copper spots to leave some areas on the board free of the metal.
- We ensure to maintain sufficient levels of residual copper, and increase trace width and line spacing to reduce the load when etching and resin filling. Wide spacing reduces the chances of shorting.
- We keep the number of pads in the inner layer to a minimum to reduce the pressure during drilling.
- With the increasing thickness, the minimum trace width must also increase to handle the higher current without excessive heating. We ensure wider traces reduce resistance and voltage drops, ensuring reliable operation under load.
- Most of our designs are multilayered which offer more routing options and can help in managing power distribution and signal integrity.
- Our PCBs are RoHS 3 EU2015/863 and REACH compliant and we have the required global certifications.
- With an ISO 9001 certified and UL approved factory, along with technologically advanced machines, we can cater to even extremely thick PCB assemblies based on your requirements.
- We are committed to producing durable PCB’s and offer timely deliveries.
If you are looking for heavy copper PCBs for your new high-power applications, we will be happy to help. In case you need any further information on our heavy copper PCBs, custom options, or want to share your requirements, feel free to contact us via phone or email.