Aluminum PCB Manufacturers , Metal Core PCB Fabrication For Automotive / Industrial Lighting

Aluminum PCBs, also known as Metal Core PCBs (MCPCB) or Thermal Clad PCBs, represent the pinnacle of thermal management for high-density power electronics. At DuxPCB, we engineer these substrates using a specialized three-layer architecture: a circuit copper layer, a thermally conductive but electrically isolating dielectric layer, and a high-grade aluminum base (typically 5052 or 6061 alloys). Our manufacturing process focuses on optimizing the interface resistance between these layers to ensure rapid heat dissipation, vital for high-performance LED arrays, power converters, and motor drives where conventional FR-4 fails due to thermal saturation.

In addition to standard single-sided configurations, DuxPCB leads the industry in Hybrid Aluminum PCB and Multilayer Metal Core designs. We integrate specialized dielectric materials like TCB-4 and JQG05 to achieve thermal conductivities up to 5W/m.K. Our hybrid stackups allow engineers to combine the thermal benefits of aluminum with the high-frequency performance of Rogers or Megtron materials. This is critical for Class 3 aerospace and defense applications where thermal stability and signal integrity are non-negotiable. Our capabilities include complex blind and buried vias within the aluminum substrate to maximize routing density while maintaining structural integrity.

• 1. Solving manufacturing failures in complex designs: We specialize in high-difficulty metal core projects that local shops or low-cost offshore vendors reject due to precision requirements or heavy copper weights.
• 2. Precision impedance and signal integrity control: DuxPCB maintains tight tolerances on dielectric thickness and trace geometry where competitors drift, ensuring consistent performance in RF and high-speed power applications.
• 3. Mastery of exotic materials: Our expertise with Rogers, Megtron, and Arlon, combined with aluminum bases, ensures zero-delamination even in the harshest thermal cycling environments.
• 4. Advanced DFM engineering: Our senior engineers perform rigorous Design for Manufacturing checks to catch layout errors, such as insufficient copper-to-edge clearance or incorrect V-cut alignments, before they result in production scrap.

Q: What is the maximum breakdown voltage for your aluminum PCB dielectrics?
A: Depending on the material choice (e.g., TCB-4 or JQG05), we can achieve breakdown voltages exceeding 3000V AC, which is critical for industrial power supply and automotive inverter applications.

Q: Can DuxPCB handle heavy copper up to 8OZ on an aluminum base?
A: Yes. We are equipped for heavy copper processing, ensuring proper etching profiles and solder mask coverage for high-current paths in industrial motor controllers.

Q: Do you offer high-reflectivity solder masks for LED applications?
A: Absolutely. We utilize Taiyo PSR-4000 series (WT03/LEW3) to provide maximum light reflectivity and UV resistance for high-output lighting systems.

For complex stackup consultations or to secure Class 3 manufacturing for your mission-critical project, please upload your Gerber files or contact our engineering team directly for a comprehensive technical review.