Thick-Copper PCB - Thicker Copper Enables Greater Power for Your Products

thick copper pcb 1

Overview of Thick-Copper PCB

  • PCBONLINE manufactures and assembles best thick-copper PCB with high electrical conductivity. Thick copper, also named 'heavy copper', means that the thickness of copper is more than the 140um (4oz), while the standard PCB weights 1 to 2oz (35um). Thick-copper PCB features the high current-carrying capacity, ideal thermal management, and high-performance reliability. Thus it is in great demand and essential in harsh work environments like temperature fluctuations.

Advantages of Thick-Copper PCB

Why Choose Thick-Copper PCB from PCBONLINE

  • • We use new drilling bit and strictly control the rotating and plunge speed to ensure the roughness of the hole ≤25um.
  • • We follow the IPC-600G Level 3 standard and can make hole copper equal to or greater than 25um.
  • • We use electrostatic spraying equipment to achieve the perfect the soldering process.
  • • Our surface ink is very uniform and does not wrinkle or bubble.
  • • We will evaluate the customer's information according to our production capacity and save cost for them.
  • • We have 21 Years of Experience in professional thick copper PCB design and production, especially in stitching and solder masking.
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Thick-Copper PCB - Manufacturing and Tech Specs


Manufacturing Process

  • PCB Layout:

    Smooth and frequent communication between electronic design and manufacturing engineers bring successful thick-copper PCB fabrication. Design engineers must be aware of the manufacturer's detail such as capacity, trace, spacing, via diameter, and square foot size, etc. Besides, PCB type requirements have to be taken into consideration like power, thru-hole structure, and material.

  • PCB Manufacturing:

    The fabrication method of the thick copper PCB is similar to that of the standard FR4 PCB. The fabricating involves the etching and plating processes like high-speed plating and deviation etching, which are to include a copper thickness in sidewalls and holes.

    First is the plating process, which thickens the thru-hole wall and plated through-wall, and improves the thermal conducting property on board surface. Then comes the etching process. The advanced etching and plating techniques are applied to achieve optimal etching margin and straight edge. During thick copper PCB fabrication, assembling of cooling fins is of high significance.

    (Note: during the production process, when the printed circuit board is subject to several cycles, the plated holes may get weak. Ideally, the holes strengthen when thick copper is added. That is why in electrical circuits, it is preferable to choose extreme current and power applications.)

    Finally is the solder mask process. For more thick copper PCB manufacturers, solder mask processing is the most difficult, but we can do that easily. The working principle of the spraying equipment is to spray soldering ink on the board in a dust-free vacuum environment. The schematic diagram is as follows.

  • calculate copper resistivity


Tech Specifications

  • The thicker the copper, the higher the cost. The cost increase results from not only the raw materials but also that the processing of thicker copper requires more time. Many thick copper PCB manufacturers have difficulty in controlling in this aspect. But we do well. You can find out the tech specs of our heavy copper PCB as below.
  • Copper Thickness
    Line Width(mm)
    Line Space(mm)
  • If the copper thickness is very thick, you can calculate the copper resistivity and resistance according to the following formula:
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Applications of Thick Copper PCB

Applications of the thick copper PCBs include but limited to:

  • 1. Defense and military applications of weapon control systems like pumping plants storage;
  • 2. Rail traction and signal and safety system applications in the automotive industry;
  • 3. With heavy mosaic layer, heavy copper PCBs are used as planar transformers;
  • 4. In pulse converters, they are very famous as they help in developing smaller transformers with the inductance of low winding leak;
  • 5. They are also used as solar power converters in solar panel;
  • 6. Amplification system and torque control applications;
  • 7. Protection and overhead relays in electrical power systems;
  • 8. Cooling HVAC (High power) systems;
  • 9. UPS systems in the telecommunication industry.

With the increase in PCB complexity, electronic engineers need to concern about PCB design rules and manufacturing techniques. Only in this way, can the product achieve the optimal balance between cost, performance requirement, and security. The benefits of features lead to minimum manufacturing risks.

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