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Aluminum PCB Manufacturing

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What are Aluminum PCBs?

Aluminum PCBs (Printed Circuit Boards) are PCBs that have a metal core, usually made of aluminum, instead of the traditional FR4 (Fiberglass Reinforced Epoxy) material. The metal core provides better thermal conductivity, allowing for more efficient heat dissipation. This makes Aluminum PCBs ideal for high-power applications such as LED lighting, power electronics, and automotive applications.

Advantages of Aluminum PCBs

Advantages of Aluminum PCBs

Environmentally Friendly

Aluminum is a highly recyclable material, and it’s non-toxic. Hence, using the metal for production promotes energy conservation thanks to its ease of assembly. So, when PCB suppliers use aluminum, it preserves environmental health.

Efficient Heat Dissipation

Aluminum Core PCBs have an aluminum core which provides excellent thermal conductivity. This allows for efficient heat dissipation, making them ideal for high-power LED lighting, automotive lighting, and power electronics.

High Durability

Aluminum is a durable material, making Aluminum Core PCBs highly resistant to wear and tear. They can withstand harsh environments, making them suitable for applications that require high reliability and durability.


Compared to traditional FR4 PCBs, Aluminum Core PCBs are lighter in weight. This makes them ideal for applications where weight is a concern, such as in aerospace and automotive industries.


Despite their advanced properties, Aluminum Core PCBs are cost-effective and can be produced at a lower cost than other advanced PCB materials.

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Specification of Aluminum Based Copper -Clad Laminate

PCBWay adheres to the highest quality standards in material selection

Part Number AL-01-B10 AL-01-B15 AL-01-B30 CS-AL-88-AD2 GL12, GL22
Thermal Conductivity
1.0 1.5 3.0 2.0 1.0 < λ≤1.5
Peel Strength
≥8 ≥8 ≥8 >9 ≥6
Breakdown Voltage
5.0 5.0 4.0 for 75um dielectric thickness
4.5 for 100um dielectric thickness
6.0 for 125um dielectric thickness
>3 ≥2
Tg (°C) 110 110 150 100 AABUS
Td (°C) 380 380 380 410 AABUS
Dk (@1MHz) 4.8 4.8 4.8 5.6 AABUS
Df (@1MHz) ≤0.02 ≤0.02 ≤0.02 0.013 AABUS
MOT 130°C 130°C 130°C 130°C -

Types of Aluminum PCBs

Hybrid Aluminum PCBs
Multilayer Aluminum PCBs
Through-hole Aluminum PCBs
Hybrid Aluminum PCBs


1-In a hybrid aluminum structure, non-thermal materials are separately processed and refined before being applied to thermal materials with an aluminum base.
2-The most common approach is to develop 2-layer or 4-layer structures typically composed of FR4 material.
3-The non-thermal material, bonded to the thermal material and aluminum base, provides rigidity and aids in heat dissipation.
4-This non-thermal bonding is preferred over using all thermal materials as it offers lower costs and higher thermal efficiency compared to conventional FR4 products.
5-The development of this product does not require heat sinks or related assembly steps.
6-Component windows are used in aluminum to accommodate through-hole components, allowing connectors and cables to pass through the board while soldering rounded corners to create a seal, eliminating the need for special washers or other expensive adapters.

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Multilayer Aluminum PCBs


1-In the high-performance power supply market, multilayer aluminum PCBs are very common and made with multilayer thermal dielectrics.
2-These structures feature one or multiple layers of circuits embedded in the dielectric, with blind vias serving as thermal vias or signal paths.
3-Single-layer designs are not very efficient, but when they come with more complex designs, they provide an ideal solution for many heat-related applications.

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Through-hole Aluminum PCBs


1-When dealing with the most complex structures, single-layer aluminum is backfilled and pre-drilled before being laminated to form the core of a multilayer structure.
2-The thermal material layers are then laminated on both sides of the aluminum using thermal bonding materials.
3-Once lamination is complete, drilling is applied for assembly.
4-To maintain proper electrical insulation, the electroplated through-holes resulting from drilling must pass through the aluminum gap.

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Ability in Process Technology

Feature Capability
Material Aluminum core (Domestic 1060), Copper core, FR4 covering
Thermal Conductivity 1.0W/(m⋅K) 1.5W/(m⋅K) 2.0W/(m⋅K) 3.0W/(m⋅K)
Min. Track/Spacing 4mil
Min. Hole Size 1layer(0.8mm) 2layers (0.2mm)
Board Thickness 0.4-3.2mm
Surface Finishing Immersion gold, OSP, Hard gold, Immersion silver, ENEPIG
Finsih copper 1-4oz
Feature Capability
Solder Mask Green, Red, Yellow, Blue, White, Black, Purple, Matte black, Matte green
Silkscreen White, Black
Via Process Tenting Vias, Plugged Vias, Vias not covered
Testing Fly Probe Testing (Free) and A.O.I. testing
Build Time 2-3 days
Lead Time 3-4 days

Featured Product Solutions

Aluminum PCBs have gained wide recognition in various lighting applications, including automotive lighting, LED applications, general lighting, and traffic lights. Also, aluminum PCBs are usually an ideal solution for tight-tolerant and high-power devices.

Manufacturing Production Capacity

Upgrading of copper deposition line
Upgrading of copper deposition line
Improve the process capability of PTH sunk copper (especially blind holes) to provide customers with high reliability products.
VCP copper plating line
VCP copper plating line
Enhance copper plating capacity, improve copper plating uniformity, and have HDI hole filling capability.
4-wire flying probe tester
4-wire flying probe tester
Better discriminate the product micro open circuit, micro short circuit, provide high precision resistance test requirements, make the product more reliable.
LDI laser direct imaging exposure machine
LDI laser direct imaging exposure machine
Achieves higher resolution while balancing the need for high alignment accuracy and high throughput.
Vacuum press
Vacuum press
Enhance the effect of laminating rigid-flex PCBs and multilayer PCBs.
Laser equipment
Laser equipment
Improve sample response speed as well as cover film,contour processing accuracy, with HDI laser drilling capability.

PCBWay's Advantages

PCBWay offers a wide range of PCB services, including flex, rigid-flex, and rigid PCB fabrication, ensuring that we can cater to diverse project requirements. We use top-grade materials and state-of-the-art equipment to guarantee optimal performance and reliability of their PCBs. PCBWay's commitment to quality, affordability, and customer satisfaction makes us a top choice for businesses and individuals seeking high-quality, customized, and reliable PCB fabrication services.

Passionate Employees
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Testing and Inspection Equipment

Salt spray tester
X-ray surface treatment thickness gauge
Metallographic section microscope
AOI inspection machine
Ion contamination tester
2D dimensional measuring instrument
Impedance tester
RoHS/HF tester

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We offer transparent pricing, with no hidden fees. Our products are made in our own factories, so you can be sure of the quality.

Applications of Aluminum PCBs

Audio device
Audio device
Power supply
Power supply
Communication electronic equipment
Communication electronic equipment
Office automation equipment
Office automation equipment
Power modules
Power modules
Lamps and lighting
Lamps and lighting


What are the advantages of using Aluminum PCBs over traditional FR4 PCBs?

Aluminum PCBs offer superior thermal performance and durability compared to traditional FR4 PCBs, making them ideal for high-power and high-reliability applications.

How do I choose the right thickness of aluminum substrate for my PCB?

The appropriate thickness of the aluminum substrate for a PCB design depends on several factors, including the required thermal performance, mechanical strength, and cost considerations.

What surface finishes are compatible with Aluminum PCBs?

Popular surface finishes for aluminum PCBs include OSP, ENIG, and HASL. However, due to the unique properties of aluminum, some surface finishes may not be suitable, and it is important to consult with your PCB manufacturer for guidance.

How do I ensure good thermal management when designing with Aluminum PCBs?

To ensure good thermal management when designing with aluminum PCBs, it is important to consider the placement and size of thermal vias, the use of thermal pads for components, and the selection of appropriate heat sinks and cooling

solutions. It is also important to perform extensive testing and analysis to validate the thermal performance of the design.

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