Heavy Copper PCB

Unleash Extreme Power Density with Heavy Copper PCBs: The Ultimate High-Current Solution

Heavy Copper PCBs redefine circuit performance by integrating copper layers ≥3 oz/ft² (up to 20 oz/ft²)—delivering unmatched current handling, thermal resilience, and mechanical strength for mission-critical applications. Unlike standard PCBs, they excel in power electronics, EV systems, and industrial controls where high currents, heat dissipation, and reliability are non-negotiable .

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Custom Parameters

Advantages

Precision Engineering

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Manufacturing Capacity and Specifications

Material

High-TG FR-4, High-Temperature FR-4

Board Thickness

1.6mm-5.0mm

Layers

1-12 Layers

Copper Thickness

≥3OZ, Normally 3-10OZ

Surface Finish

HASL, ENIG, Immersion Tin

Min. Trace/Space

0.25mm, arise with copper thickness

Min. Hole Size

0.3mm-0.5mm

Solder Mask

Optional

Silkscreen

Optional

Why Heavy Copper Dominates High-Power Designs: 5 Core Advantages

Unrivaled Current Capacity: Carry 10–20× Higher Current than standard PCBs: A 4 oz copper trace at 10 mm width handles 100+ amps without overheating, eliminating complex bus bars or cables. Ideal for EV battery management (BMS), solar inverters, and industrial fuse boxes . Reduce I²R Losses by 70%: Thicker copper slashes resistive heating, preventing voltage drops in power distribution networks .
Superior Thermal Management: 401 W/m·K Thermal Conductivity: Copper acts as an integrated heatsink, dissipating heat 150× faster than FR-4. Enables stable operation at 150°C+ in power converters or LED drivers without external coolers. Near-Zero Thermal Strain: Matches component CTE, preventing solder cracks during rapid thermal cycling (-55°C to 200°C) .
Extreme Mechanical Durability: 3× Higher Vibration/Shock Resistance: Reinforced copper layers withstand stress in automotive engines, aerospace avionics, and heavy machinery .15+ Year Lifespan: Resists corrosion, moisture, and thermal fatigue—critical for offshore rigs or nuclear reactors .
Space & Weight Optimization: Replace Wiring Harnesses: Consolidate high-power traces onto a single board, cutting assembly size by 50% (e.g., in industrial control panels) . Enable HDI in Power Circuits: Support 20-μm traces alongside 10 oz copper zones for mixed-signal designs (e.g., motor controllers) 36.
Enhanced Reliability in Harsh Environments: Zero Degradation under UV, chemicals, or radiation—certified for aerospace (MIL-STD-202) and automotive (IATF 16949) . Hermetic Sealing: 0% moisture absorption ensures stability in humid/outdoor settings .

Technical Mastery: Materials & Manufacturing Innovations

Material Science
High-Tg Laminates	FR-4 with Tg >170°C or polyimide for 200°C+ stability.
Ceramic Hybrids	AlN/DBC substrates for 300 W/m·K thermal conductivity (e.g., fusion reactor sensors).
Precision Fabrication
Controlled Depth Etching	Achieve steep 3:1 aspect ratios on 0.49 mm ultra-thick copper layers without undercut.
Multi-Step Lamination	Prevent delamination/blistering during 400°C+ presses for 20+ layer boards.

Industry Applications: Where Heavy Copper PCBs Excel

Industry	Critical Use Cases	Performance Impact
Automotive	EV chargers, 800V BMS, ignition systems	Survives 200°C engine bays; 50% weight reduction vs. wiring
Power Electronics	Solar inverters (600V+), grid transformers	40% lower cooling costs; handles 200A continuous current
Industrial Automation	Motor drives, robotic controllers	Withstands 100,000+ mechanical flex cycles; IP67 rated
Aerospace & Defense	Avionics power distribution, radar T/R modules	Radiation-hardened; -55°C to 200°C operation
High-Power LEDs	Stadium lighting, automotive headlamps	Eliminates heatsinks; sustains 120°C junction temps

Manufacturing Equipment at BENLIDA

contains the mostadvanced equipment required for the manufacture and assembly of your PCBs. Whether you'relooking for standard quick turn PCBs or boards with the tightest tolerances, made from exoticmetals, there's a reason Sierra Circuits leads the industry in quality and performance.

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