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Heavy Copper PCB
Heavy Copper PCB refers to a type of printed circuit board (PCB) that has a thicker copper layer compared to standard PCBs. In general, heavy copper PCBs have copper thicknesses of more than 3 ounces per square foot (oz/ft²), which is about 105 µm, and can go up to 20 oz/ft² or more.
These thicker copper layers can handle higher currents, increase the board’s ability to dissipate heat, and improve the mechanical strength of the PCB. Heavy copper PCBs are often used in high-power applications such as power electronics, power supplies, and automotive applications.
Designing and manufacturing heavy copper PCBs require special attention, as they can be more challenging to manufacture compared to standard PCBs due to the increased copper thickness. Therefore, it is essential to work with experienced PCB manufacturers who have the necessary expertise and equipment to produce heavy copper PCBs reliably and efficiently.
What is a Heavy Copper PCB?
Heavy Copper PCB is a type of printed circuit board that uses significantly thicker copper layers than standard boards, typically defined as having 3 oz/ft² (about 105 µm) or more of finished copper on inner or outer layers. Some manufacturers classify “heavy” starting at 4 oz or 5 oz, while “extreme” heavy copper can reach 15 oz to 30 oz or higher.
🔍 What Makes It Different
Standard PCBs commonly use ½ oz to 2 oz copper (17-70 µm). Heavy copper boards increase that thickness to handle much higher currents and improve heat dissipation. This extra copper also provides greater mechanical strength at connector sites and plated through-holes (PTHs), which is critical for boards exposed to vibration or thermal cycling.
⚙️ Key Manufacturing Considerations
Producing heavy copper requires specialized techniques because etching thick copper removes material both vertically and laterally (undercut), which limits fine feature resolution. 5 oz copper can have lateral undercut of 100-150 µm per side, so trace widths below roughly 8 mil become unreliable. The process often combines plating to build thickness with differential etching to achieve more vertical sidewalls. Plating times are much longer, and lamination needs high-resin prepreg to fill gaps around tall copper traces without voids.
🎯 Where It Is Used
Heavy copper PCBs are common in power supplies, DC-DC converters, inverters, motor drives, EV chargers, solar power systems, and high-current bus bars. They allow designers to integrate bus bars directly into the board instead of using external heavy-gauge wiring, improving reliability and reducing assembly complexity.
💡 Design Trade-offs
One practical approach is mixed copper construction—using heavy copper only on power layers while keeping signal layers at standard weight. This balances current capacity with the ability to route fine-pitch components and often costs less than making every layer heavy. A 6-layer 1 oz board with paralleled power layers is sometimes more cost-effective than a 4-layer 3 oz board, though heavy copper wins when board area is tightly constrained.
Need Heavy Copper PCB?
Need Heavy Copper PCBs for high-power applications? Choose ELIPCB – the expert PCB manufacturer with up to 10oz copper thickness capabilities.
ELIPCB Heavy Copper PCB Capabilities
ELIPCB (Electronic Interconnect Printed Circuit Boards) is a PCB manufacturing company that offers a range of services including heavy copper PCB capabilities. Heavy copper PCBs are boards that have thicker copper layers than standard PCBs, which makes them ideal for applications that require high power or high current handling.
ELIPCB offers heavy copper PCBs with copper thicknesses up to 10 ounces per square foot (or 336 microns), which is significantly thicker than standard PCBs that typically have copper thicknesses between 1-3 ounces per square foot. ELIPCB can also manufacture heavy copper PCBs with multiple layers and with up to 6oz copper thickness for inner layers.
ELIPCB has a team of experienced engineers who can work with customers to design and manufacture custom heavy copper PCBs to meet their specific requirements. They use advanced equipment and technology to ensure high-quality products and fast turnaround times.
In addition to heavy copper PCBs, ELIPCB also offers a range of other services including high frequency PCBs, flexible and rigid-flex PCBs, and HDI PCBs. They can also provide PCB assembly and testing services.