Aluminum PCB Manufacturer

2 Layer, Double Sided Aluminum PCB Manufacturing Service

Q: What are the typical applications of 2 layer aluminum PCB?

Some common applications of 2 layer aluminum PCBs include: LED lighting drivers Automotive electronics Power conversion/distribution Industrial control systems Telecom/Networking hardware Aerospace and defense electronics In these applications, the high thermal performance of aluminum PCBs helps transfer heat efficiently from power devices. The simple 2 layer construction reduces fabrication costs.

We provide high-quality manufacturing services for double-sided aluminum PCBs. Our aluminum PCBs are known for their excellent heat dissipation, corrosion resistance, and reliability.

What is 2 Layer Aluminum PCB?

2-layer aluminum PCB, or double-sided aluminum PCB is a type of aluminum printed circuit board that features a thin layer of aluminum on both sides of the board, providing excellent heat dissipation and thermal management properties. The aluminum layer acts as a heat sink, allowing the board to dissipate heat more efficiently than traditional PCBs.

Common specifications for 2 layer aluminum PCBs are:

Aluminum thickness: 0.8mm to 3.0mm
Dielectric layer thickness: 0.1mm to 0.3mm
Copper thickness after plating: 20μm to 35μm
Minimum track/spacing: 6mil/6mil (0.15mm/0.15mm)
Minimum hole size: 0.3mm
Hole to hole spacing: 0.6mm
Finished board thickness tolerance: ±0.1mm

Our PCB manufacturing facility specializes in producing high-quality double-sided aluminum PCBs for a wide range of applications. Our experienced team and state-of-the-art equipment ensure that we can deliver reliable and efficient PCBs that meet our customers’ exact specifications.

The Structure and Components of 2 Layer Aluminum PCBs

The structure of a 2 layer aluminum PCB typically consists of a thin layer of aluminum foil that is laminated to both sides of a core material, such as FR-4 or ceramic. The core material provides the structural integrity of the board, while the aluminum layers act as a heat sink to dissipate heat generated by the components on the board.

The two aluminum layers are typically connected by a series of vias, which allow for electrical connections to be made between the top and bottom layers of the board. The vias are typically drilled through the core material and then plated with copper to create a conductive path between the two aluminum layers.

On top of the aluminum layers, a layer of copper is applied, which is then etched away to create the desired circuit pattern. The remaining copper traces and pads are then coated with a layer of solder mask to protect them from oxidation and to provide insulation between the copper and other components on the board.

Finally, a silkscreen layer is applied to the board, which is used to label the various components and provide other information about the board, such as the manufacturer’s logo or part number.

Overall, the structure of a 2-layer aluminum PCB is similar to that of a traditional 2-layer PCB, but with the added benefit of improved thermal performance thanks to the use of aluminum layers as heat sinks.

Benefits of 2 Layer Aluminum PCB

Key Features of Double Sided Aluminum PCBs

Double sided aluminum PCBs offer several unique features and benefits that make them a popular choice for a variety of applications. Here are some of the key features of double sided aluminum PCBs:

Excellent heat dissipation:

Double sided aluminum PCBs are designed with a thin layer of aluminum on both sides of the board, which provides excellent thermal conductivity and helps to dissipate heat more efficiently than other types of PCBs. This makes them ideal for high-power applications where heat management is critical.

High power handling capacity

Double sided aluminum PCBs can handle higher levels of power than other types of PCBs, thanks to their excellent heat dissipation properties. This means they can be used in applications that require high power levels, such as power electronics, automotive electronics, and LED lighting.

Improved reliability

The use of aluminum in double sided aluminum PCBs also makes them more durable and reliable than other types of PCBs. Aluminum is highly resistant to corrosion and oxidation, which helps to prevent the degradation of the board over time.

Cost-effective

Despite their many advantages, double sided aluminum PCBs are relatively cost-effective compared to other types of high-performance PCBs. This makes them a popular choice for applications where cost is a concern.

Easy to design and manufacture

Double sided aluminum PCBs can be designed and manufactured using standard PCB fabrication processes, which makes them easy to integrate into existing designs and manufacturing processes.

Applications of Double Sided Aluminum PCB

Double sided aluminum PCBs are widely used in a variety of applications that require high thermal performance and reliable operation. Here are some of the key applications of double-sided aluminum PCBs:

LED Lighting: High-power LED lighting systems require efficient thermal management to ensure reliable and long-lasting operation. Double-sided aluminum PCBs provide excellent heat dissipation, making them an ideal choice for LED lighting applications.
Automotive Electronics: Automotive electronics often operate in high-temperature environments, making reliable thermal management critical. Double-sided aluminum PCBs can handle high power levels and dissipate heat effectively, making them well-suited for automotive applications such as power modules, LED headlights, and motor control systems.
Power Electronics: Power electronics, such as power supplies and inverters, generate a lot of heat and require efficient thermal management to ensure reliable operation. Double-sided aluminum PCBs are capable of handling high power levels and dissipating heat effectively, making them an excellent choice for power electronics applications.
Telecommunications: Telecommunications equipment, such as base stations and routers, require reliable and efficient thermal management to ensure optimal performance. Double-sided aluminum PCBs can handle high power levels and dissipate heat effectively, making them well-suited for telecommunications applications.
Medical Devices: Medical devices often require precise temperature control and reliable operation, making efficient thermal management critical. Double-sided aluminum PCBs can provide reliable operation and precise temperature control, making them a popular choice for medical device applications.

Overall, the superior thermal performance and reliability of double-sided aluminum PCBs make them an excellent choice for a wide range of applications where thermal management is critical.

Differences between Double Sided, Single Sided, and Multilayer Aluminum PCBs

Here’s a comparison of the differences between double-sided aluminum PCBs, single-sided aluminum PCBs, and multilayer aluminum PCBs:

Feature	Double Sided Aluminum PCBs	Single Sided Aluminum PCBs	Multilayer Aluminum PCBs
Layer count	2	1	3 or more
Copper thickness	Thick	Thin	Varies
Component density	Moderate to high	Low	High
Manufacturing process	Similar to traditional PCBs	Similar to traditional PCBs	More complex than single or double-sided PCBs
Cost	Less expensive	Least expensive	Most expensive
Electrical performance	Good	Limited by single layer	Good
Thermal performance	Excellent	Good	Good to excellent

As shown in the table, double-sided aluminum PCBs offer better thermal and electrical performance compared to single-sided aluminum PCBs due to their two layers of aluminum and thicker copper layers. They also have higher component density capabilities, making them ideal for more complex designs.

Multilayer aluminum PCBs can offer higher component density than double-sided aluminum PCBs due to their multiple layers, but they also require a more complex manufacturing process and are typically the most expensive option.

Overall, the choice between double-sided aluminum PCBs, single-sided aluminum PCBs, and multilayer aluminum PCBs depends on the specific requirements of the application, including component density, electrical performance, thermal performance, and cost.

The Manufacturing Process of 2 Layer Aluminum PCB

The manufacturing process for double sided aluminum PCBs involves several steps. Here is an overview of the process:

Substrate preparation: The first step is to prepare the aluminum substrate. The substrate is cleaned and coated with a layer of dielectric material, which acts as the insulating layer between the two layers of aluminum.
Imaging and etching: The next step is to image the PCB design onto the substrate using a photoresist. The photoresist is exposed to UV light through a mask and then developed to remove the unexposed areas. The substrate is then etched to remove the exposed aluminum, leaving behind the circuit traces.
Drilling: After the circuit traces are formed, the PCB is drilled to create the necessary holes for component mounting.
Plating: The PCB is then plated with a layer of copper to increase its conductivity and provide a surface for component mounting. The plating process involves several steps, including cleaning, etching, and deposition of the copper layer.
Solder mask and silkscreen: Once the copper layer is in place, the PCB is coated with a layer of solder mask to protect the circuit traces and prevent solder bridging. A silkscreen layer is also applied to add component labels and other markings.
Surface finish: Finally, a surface finish is applied to protect the copper and prevent oxidation. Common surface finishes for double-sided aluminum PCBs include HASL (hot air solder leveling), ENIG (electroless nickel immersion gold), and OSP (organic solderability preservatives).

Once the PCB is complete, it undergoes a series of quality control checks to ensure that it meets the necessary specifications and standards. The PCB can then be shipped to the customer for use in their application.

Aluminum PCB Manufacturing Service

We offer a comprehensive aluminum PCB manufacturing service that covers the entire production process, from design to delivery. Our manufacturing capabilities include the production of single-sided, double-sided, flexible aluminum PCB, and multilayer aluminum PCBs, as well as a range of surface finishes to suit different applications.

Aluminum PCB Fabrication Capabilities

Capability	Details
Layers	Single-sided, double-sided, and multilayer
Substrate material	High-quality aluminum substrate with dielectric layer
Minimum trace width/spacing	0.1mm
Minimum hole size	0.2mm
Maximum board size	600mm x 1200mm
Copper thickness	1oz to 6oz
Surface finish	HASL, ENIG, OSP
Solder mask color	Green, black, white, blue, red, yellow, and more
Silkscreen color	White, black, yellow, and more
Quality control	Rigorous testing and inspection to ensure compliance with specs

At our company, we pride ourselves on providing excellent technical support and customer service to ensure that our customers have a seamless and satisfying experience throughout the entire process of ordering and receiving their aluminum PCBs.

Our technical support team is comprised of experienced engineers and technicians who have a deep understanding of the PCB manufacturing process and can provide expert guidance and advice on all aspects of design and fabrication. They work closely with our customers to understand their specific requirements and provide tailored solutions that meet their needs.

In addition, our customer service team is available to provide prompt and friendly assistance with any questions or concerns that may arise during the ordering process or after delivery. We understand the importance of open communication and strive to maintain clear and timely communication with our customers throughout the entire process.

Furthermore, we offer a range of additional services to ensure that our customers receive the best possible support, including:

Customized solutions: We work closely with our customers to develop customized solutions that meet their unique requirements and specifications.
Prototyping services: We offer prototyping services to help our customers test and refine their designs before moving into full production.
Fast turnaround times: We are committed to providing fast turnaround times to help our customers meet tight deadlines and keep their projects on schedule.

Overall, our goal is to provide our customers with a hassle-free experience and ensure that they receive the highest quality aluminum PCBs and the best possible support and service.

Customer Feedback

We take great pride in the quality of our products and services, and our customers’ satisfaction is of utmost importance to us. Here are some examples of feedback and reviews we have received from our customers:

We have been working with this company for several years now, and they have consistently provided us with high-quality aluminum PCBs and excellent customer service. We highly recommend them."

"The team at this company was very helpful in guiding us through the PCB design and manufacturing process. They provided expert advice and delivered our order on time and to our exact specifications."

"We have been using this company for our aluminum PCB needs for several years now, and we have never been disappointed. Their fast turnaround times and high-quality products are unmatched in the industry."

We value our customers’ feedback and strive to continually improve our products and services to meet their needs and exceed their expectations.

FAQs for Aluminum PCB

What is the maximum size of the aluminum PCBs you can fabricate?

We can fabricate aluminum PCBs up to 600mm x 1200mm in size.

What is the minimum order quantity (MOQ) for aluminum PCBs?

Our MOQ for aluminum PCBs is 5 pieces.

What is the typical lead time for aluminum PCB fabrication?

Our lead time for aluminum PCB fabrication is usually 5-7 business days, but it may vary depending on the complexity of the design and the quantity ordered.

What file formats do you accept for PCB design files?

We accept Gerber, ODB++, Eagle, Altium, and other common PCB design file formats.

What is the maximum number of layers for aluminum PCBs?

We can fabricate aluminum PCBs up to 4 layers.

What are the key design guidelines for 2 layer aluminum PCBs?

The main design guidelines to follow when designing 2-layer aluminum PCBs are:

Maintain adequate clearance between traces and holes/edges due to reduced insulation. Clearances of at least 0.2mm are typical.
Account for the thermal expansion of the aluminum when sizing the board and copper traces. Leave adequate margins to avoid thermal stress.
Use thermal relief connections for components soldered to pads to enhance reliability.
Avoid acute angles on copper traces. Use rounded corners instead.
Ensure sufficient trace widths to handle high current loads.
Use redundant vias when possible to improve heat dissipation.

Following these guidelines helps ensure the reliable performance of 2-layer aluminum PCBs. Please consult us for any further PCB design advice needed.

What are the typical applications of 2 layer aluminum PCB?

Some common applications of 2 layer aluminum PCBs include:

In these applications, the high thermal performance of aluminum PCBs helps transfer heat efficiently from power devices. The simple 2 layer construction reduces fabrication costs.