Thick-Copper circuit boards

Compared to standard PCBs, thick copper PCBs offer decisive advantages:

• Higher current carrying capacity: The same track width can carry significantly higher currents - with 140µm copper, the resistance drops to around a quarter compared to 35µm.
• Better heat dissipation: Copper conducts heat around 1,300 times better than FR4 (approx. 400W/mK vs. 0.3W/mK). The thick copper layers act as internal heat sinks.
• Greater mechanical stability: The additional copper thickness increases the rigidity of the PCB and improves vibration resistance.
• Space saving: Thick copper can replace traditional busbars or cable harnesses and enables more compact designs.

Thick copper PCBs are used wherever high currents flow or large amounts of heat need to be dissipated:

• Power electronics: power supply units, frequency converters, switching power supplies
• Automotive: electric vehicles (battery management systems, chargers, inverters), fuse boxes
• Industrial electronics: servo drives, welding equipment, solar inverters
• Aerospace & defence: Uninterruptible power supplies, high-performance radars
• Medical technology: High-performance diagnostic devices

Thick copper PCBs offer decisive advantages for thermal management:

• Improved heat conduction: copper conducts heat at approx. 400W/mK - this is around 1,300 times better than FR4 (approx. 0.3W/mK). The thick copper layers act as internal heat sinks.
• Thermal vias: Thermal vias strategically placed under power components form important vertical heat dissipation paths.
• Self-cooling effect: Heavy copper structures can dissipate up to 20% of the total temperature themselves and act as heat exchangers.
• Flatness: Uniform copper distribution across the entire PCB minimises thermally induced deformations and delamination risks.

Yes, thick copper PCBs are significantly more expensive to purchase. The additional costs result from

• Higher raw material costs (more copper, special laminates)
• Longer production times (especially for etching)
• Higher tool wear
• More complex process management
• Potentially lower yields

Important note: Despite higher unit costs, the overall price of your end product may fall, as thick copper PCBs often replace several components (cables, connectors, busbars, separate heat sinks) and simplify assembly. With high quantities, the cost quickly pays for itself.