Many important factors are necessary when selecting a metal core PCB manufacturer. These include the quality of the copper and aluminum used as dielectric materials. This metal material should withstand high temperatures and protect the circuit board’s elements. The manufacturer should also have extensive experience in PCB production and be able to meet your delivery deadlines.
Heat dissipation
A good metal core PCB manufacturer can make a PCB that can handle high temperatures. They also can selectively apply copper layers for increased current carrying capacity. This allows manufacturers to avoid problems with thermal expansion and contraction problems and maximize their equipment’s durability.
The standard epoxy used in FR-4 reaches a glass transition temperature (GTT) of 130 degrees Celsius. Once epoxy reaches that temperature, it becomes significantly more pliable and experiences a dramatic increase in CTE. However, long-term operations near this temperature can result in board failure, interlayer shorts, and even complete delamination of copper from its substrate. Further, leaded solder requires temperatures of up to 225 degrees for moisturizing joints. A metal-core printed circuit board manufacturer will be able to meet these demands with ease.
A metal core printed circuit board manufacturer can provide a product with superior thermal PCB compared to a conventional FR-4 substrate. This type of PCB also features a metal base layer, making it more durable and able to withstand more pressure and vibrations. It can also be a heat sink, dissipating excess heat and preventing component damage.
Thermal conductivity
Unlike FR-4, a metal core PCB can withstand higher temperatures and have better thermal PCB. The 1.6mm thickness of these boards allows the heat from electronic components to escape efficiently. Additionally, their thin copper layer minimizes overall PCB thickness, which can help to reduce manufacturing costs.
Thermal management is essential for modern electronics. If the heat does not transfer properly, the PCB could fail or malfunction. The high thermal PCB will prevent excessive heat build-up and protect components from failure. A Metal core PCB also minimizes the risk of PCB damage from extreme temperatures.
Metal core PCBs are especially helpful for applications that generate immense heat. Conventional fans and cooling methods cannot keep up with the heat produced by these applications. In addition, metal core PCB offers high illumination, which can be impossible with traditional LEDs. Therefore, this type of PCB is increasingly helpful in lighting applications. However, metal core PCBs have their limitations.
Solder mask
There are several different types of solder masks, and choosing the right one for your project is crucial. You should consider the physical dimensions of your board, the components you will use, and the final application. In addition, some industries require a specific mask type, such as the medical or aerospace industries.
When choosing a metal core PCB manufacturer, choose a company that uses a green or blue mask. A green mask is generally more comfortable and has fewer visible scratches. However, choosing a blue or black mask may be more challenging to see, as these colors are more difficult to control visually. The standard color for a solder mask is green, and most PCB manufacturers carry it in their stock. However, if you want to select a different color, you should ask the PCB manufacturer which shade they use.
While solder mask color does not significantly impact the functionality of a circuit board, it is essential to note that it plays a critical role in PCB prototyping. In the case of prototyping, high-contrast colors are ideal for trace visibility. Manufacturers may also vary the color of a PCB to distinguish between prototype and production boards, as well as in mixed assembly environments.
Cost
While the process for metal core PCB design is very similar to that of other printed circuit boards, the process for metal fabrication is very different. First, metal fabrication requires special care and consideration, such as proper hole wall preparation. Once the holes are ready, we remove the remaining filler material, and the boards are ready for lamination. The rest of the process follows standard manufacturing protocols.
Copper and aluminum are the most common metals used for manufacturing PCBs. Aluminum is a relatively cheap metal and a superior metal material for heat transfer and electrical isolation. Copper is much more expensive than aluminum, but copper-based PCBs have better properties for higher temperatures.
Metal-core printed circuit board is usually thicker. Depending on the thickness, these boards can have up to six layers. Each layer must be similar in thickness to avoid warping, which could affect LED performance. Additionally, a metal-core PCB should not have plated through holes. These can lead to electrical shorts and poor performance.
Technical Specifications of Metal Core Aluminum PCBs
A metal core Aluminum PCB is made of two layers: a copper foil layer and a dielectric polymer layer. The former is much thicker than the latter, which means a higher current-carrying capacity. The aluminum substrate and dielectric polymer layer are highly thermally conductive and have a low thermal resistance. A selective membrane layer caps both layers. The temperature of the membrane layer is below 120 degrees, while that of the aluminum base is around 250 degrees.
Designing a metal core PCB
When designing a PCB, it is essential to consider the metal used. Aluminum is one of the most popular materials for PCBs, but copper and stainless steel are also options. Aluminum is ideal because it is non-toxic and can easily be extracted and purified. It also provides excellent thermal conductivity.
When designing a PCB with a metal core, it is essential to remember that metal PCBs often have special mechanical components and enclosures. Fortunately, Altium Designer has native 3D design tools for designing a metal-core PCB. Plus, you can release your designs to collaborators through Altium 365, a cloud-based platform for circuit board design collaboration.
A Metal core PCB is also great for high-temperature applications because they dissipate heat efficiently. Unlike FR-4, a metal core PCB can withstand some of the highest temperatures in the market. This is a big advantage over FR-4, which can eventually cause physical failure or damage electronics.
Manufacturing process
We can produce Metal core aluminum PCBs by a multi-step process involving a metal core, copper foil, and a polymer dielectric. The first step consists of preparing a rough metal core on which the copper foil and PP bond. The next step involves the preparation of a single-sided CCL, followed by the 2nd drilling step.
The manufacturing process of aluminum PCBs is similar to that of FR4 PCBs. It comprises a dielectric layer, a copper foil layer, and an aluminum base layer. However, the copper layer used in aluminum PCBs is thicker than normal CCLs, resulting in higher current carrying capacity. On the other hand, the dielectric layer has a low thermal resistance.
Thermal dissipation
Unlike conventional PCBs, metal core aluminum PCB has excellent thermal dissipation properties. These boards are also lightweight, which helps minimize product size and assembly costs. Furthermore, they don’t need additional heat sinks. Thus, they are the perfect choice for applications where heat dissipation is a top priority.
While FR-4 is an excellent substrate for PCBs, metal core aluminum PCB is ideal for thermal conductivity. Their aluminum base and thermally conductive dielectric layer help to direct heat away from electronic components. This results in increased equipment durability. Moreover, these PCBs are recyclable.
Printed circuit boards must dissipate heat efficiently to avoid malfunction. Conventional fans can’t effectively cool electronics that produce a large amount of heat. Therefore, conductive cooling through metal core aluminum PCB is the best solution for such applications. This process transfers heat from the hot part to a cooler one by direct contact. Heat constantly seeks cooler objects. Thus the aluminum substrate offers superior heat dissipation and heat transfer characteristics.
Circuit layer
Aluminum PCBs are similar to conventional PCBs, but the base consists of aluminum. The metal layer acts as a heat-dissipating layer and protects essential components from damaging heat. Another advantage of aluminum PCBs is their low cost. Multilayer aluminum PCBs contain multiple layers of circuitry and thermally conductive dielectrics.
Aluminum PCB is also available in double-sided configurations. They are ideal for high-performance applications that produce heat. They are more efficient in heat dissipation than traditional FR-4 substrates. Furthermore, aluminum core PCB is recyclable, non-toxic, and has high thermal conductivity.
Aluminum PCBs are the most common choice for a metal core PCB. These PCBs are ideal for power device surface mount technology. These boards are highly reliable and exhibit excellent dimensional stability. In addition, they reduce the overall product volume.
Dielectric layer
The basic building blocks for a metal core PCB are a metal base, a metal layer, and a dielectric layer. The metal layer is usually made of aluminum but can also consist of copper or stainless steel. These boards are also known as metal-backed PCBs because they have a metal layer on the back. Unlike a copper-core board, a metal-core PCB cannot be routed with traces but must be routed with through-holes to connect the dielectric layers and bring the ground to the metal layer.
Another option for an aluminum PCB is the flexible type. Flexible aluminum PCBs are made with a polyimide resin system with ceramic fillers to provide excellent electrical insulation and thermal conductivity. Flexible aluminum PCBs also eliminates the need for expensive cables and fixtures. Another type of aluminum PCB is the hybrid type, which uses a thermally conductive polymer layer and a metal core to improve its rigidity. Finally, multilayer aluminum PCBs use multiple layers of thermally conductive metal material. This is advantageous for complex designs because it can dissipate heat more efficiently.
Benefits of Metal Core Printed Circuit Boards
Metal core PCBs are ideal for many electronic projects, as they provide superior mechanical and thermal properties. These materials are also non-toxic and environmentally friendly. These boards are the way to go if you want to develop a new product. However, choosing the right manufacturer for your project can be tricky, and inexperienced producers are everywhere. You’ll need a PCB manufacturer with an excellent reputation for producing quality products and meeting deadlines.
Thermally efficient
A metal core PCB is a printed circuit board with a metal core. The benefits of this type of board are numerous, including increased heat dissipation and improved light output. These boards are also resistant to high temperatures, making them a good choice for LED-based products. In addition to their increased heat dissipation properties, these boards also feature good thermal conductivity.
A Metal core PCB is ideal for high-power components such as LED lighting, motor control in electric vehicles, and solid-state relays. Due to their ability to transfer heat quickly, these boards are more efficient than conventional FR-4 substrates. Aluminum is the most common metal in this type of PCB and has high thermal conductivity.
Metal core printed circuit board is widely helpful in automotive, audio, motor control, and power conversion applications. Their thermal conductivity and superior attachment abilities make them an excellent choice for these applications. They also offer better electromagnetic shielding and capacitive coupling. Thermal vias are not typically used with a metal core PCB but are sometimes used to improve the electrical connection.
Mechanically robust
Metal core PCBs are ideal for applications where high temperature, thermal cycling, moisture, and frequent mechanical shocks are required. This type of circuit board offers high thermal conductivity and superior structural integrity. It also provides adequate thickness for mounting hardware. However, selecting a reputable manufacturer with extensive experience in manufacturing PCBs is essential.
Compared to FR-4, a metal core PCB can handle high temperatures more efficiently. This helps lower the overall heat level of the PCB. Additionally, this circuit board can use a thin copper layer, reducing overall PCB thickness and manufacturing costs.
A metal core PCB must comply with specific design guidelines. The board should have a metal core and an adequate thermal management system to prevent overheating. The design software used should be able to handle metal core printed circuit board and have native 3D tools for metal core PCB design. Furthermore, it should support Gerber drafting and schematics so that the final board figure resembles the design.
Non-toxic
Metal core printed circuit boards are made with a metal core to improve power density and reduce device temperature. These circuit boards feature copper foil, aluminum, and other metal alloys for excellent electrical isolation and heat transfer. They are essential in a variety of electrical equipment. Aluminum is cheap but also offers excellent thermal conductivity. This means less power helps heat the circuit board, which saves energy. Aluminum is also an effective insulator, preventing electrical currents from traveling through the circuit board.
Copper and aluminum are the two most common metals used to make a metal core PCB. Unlike multilayer PCBs, metal core boards are mono or double-sided. In addition, they are recyclable, making them better for the environment. Aluminum is easily extracted and purified, making it a popular option for PCB production.
The metal concentrations in laptop PCBs are increasing due to the general increase in metal prices. As a result, researchers are looking into ways to reduce metal concentrations. One way to do this is by recycling the PCBs themselves. Aluminum core PCB is a highly versatile metal that delivers strength and durability. It also helps prevent accidental fractures and is environmentally friendly. Furthermore, aluminum core PCB manufacturing is simple and energy-efficient.
Environmentally friendly
Metal core PCBs are an excellent choice for environmentally-friendly applications. They consist of lightweight and durable aluminum that adds strength and resilience to the circuit board. Aluminum also dissipates heat, protecting critical components from damaging temperatures. Among the environmental benefits of aluminum-based PCBs, they are recyclable and easy to assemble.
The main application of metal PCBs is in electric vehicles’ LED lighting, solid-state relays, and motor control. These materials offer improved thermal performance compared to traditional FR-4 substrates, making them a perfect choice for these high-power applications. They also provide better thermal conductivity, meaning electronic components will absorb less heat. However, despite these benefits, a metal core printed circuit board is prone to moisture damage.
Metal core PCBs are also excellent for high-temperature applications. The thin-film dielectric layer in the board’s middle helps dissipate heat efficiently. As a result, they can withstand the highest temperature levels in the marketplace. In contrast to FR-4, which can damage the circuit board, a metal core PCB can withstand extreme temperatures without causing system failure or physical damage.
Design for Metal Core PCBs
We often construct Multilayer PCBs with a metal core. This core gives the PCB its rigidity. A Metal core printed circuit board consists of Aluminum, Iron, or Copper. Each of these metals has its benefits and drawbacks. The metal plate on the bottom side of the PCB is the thickest element in the structure. It is also the easiest to purchase and does not require a solder mask or surface finish.
Multilayer metal core PCBs
A multilayer metal core PCB is a printed circuit board with a metal core. It differs from conventional FR4 PCBs in several ways. For example, it consists of multiple copper conductor layers instead of just one and has an additional pressing step to bond the layers together. This type of board has several advantages over conventional FR4 PCBs, including the fact that it does not require thermal relief vias. In addition, it also requires less drilling and only a few large holes for mounting.
We can manufacture Multilayer PCBs with a variety of different materials. The most common is aluminum, but it is possible to find multilayer metal core PCB in various alloys, such as copper. However, they are also generally more expensive because of their higher thermal conductivity.
A metal PCB is particularly suitable for high-power applications. These PCBs can transfer heat away from high-power components. Common applications for this type of board include LED lighting systems, solid-state relays, and automotive power circuits. This technology allows circuits to run more efficiently, improves reliability, and extends component life.
Aluminum cores
Aluminum core PCB is widely helpful in power supply products. They offer several advantages over conventional circuit boards, including superior heat transfer capacity and firmness. Additionally, they can help cool components without the problems associated with fragile ceramics. However, to make the most of this new technology, there are some steps that designers need to follow to ensure that their finished circuit boards perform to expectations.
First, designers must consider the environment in which they will operate. Aluminum-core PCB is environmentally friendly, lightweight, and can withstand high temperatures. Additionally, they are recyclable. These properties make them an excellent choice for many different types of products. Moreover, they have a low cost.
When designing an aluminum core PCB, designers need to consider the material used, the conductive dielectric, and the basic structure of the circuit board. They must also consider manufacturing costs.
Iron cores
PCBs with a metal core is ideal for industrial applications. These boards are thermally efficient yet still have high mechanical strength. As a result, they can be helpful for various purposes in the aerospace, power electronics, and lighting industries. However, it is essential to remember that these boards often experience high heat, which can harm the board if it does not have the right design.
One way to design a metal-core printed circuit board is with a specialized CAD tool. This software includes a comprehensive library of standard materials and routing features. It also checks your designs against specific metal-core PCB design guidelines. It’s also possible to use a PCB stackup manager that can define the positions of metal cores on a circuit board. This lays the foundation for the placement of components and traces.
Another option is to make your PCBs with an aluminum or copper core. This type of PCB will generally have a higher thermal conductivity. This allows the heat generated by the electronic components to dissipate from the board. Additionally, this type of PCB is more affordable than aluminum-core PCBs.
Copper cores
Copper cores for a metal core PCB have several advantages. First, they have better thermal conductivity than the other materials and better adhesion to FR4. Secondly, copper is easy to obtain. We can drill it with low-angle bits and easily oxy-coated. Finally, they can be used for high-temperature applications and as a multilayer layup.
Another significant advantage of a metal core PCB is that they are available in various thicknesses, ranging from 30 mils to 120 mils. Unlike their traditional counterparts, they do not require vias, which need large mounting holes. Moreover, they can be used for higher-density designs and operate at high currents.
Metal core PCB manufacturers use the latest technologies in manufacturing PCB boards, which helps reduce assembly costs, achieve tighter integration of support and power circuits, and improve thermal conductivity. Without printed circuit boards, modern technology would be impossible to imagine. These boards replaced electrical radio products and harnesses made of connecting wires. But this evolution in the industry required new industrial technologies to make these PCBs.
