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Metal PCB Materials Differences: Aluminum Vs. Copper Core Vs. Iron Based
Introduction
Metal core printed circuit boards (MCPCB) refer to boards which incorporate a metal plate or substrate as
the central layer instead of the typical FR4 dielectric. Metals like aluminum, copper or iron alloys can be
used as the core material in MCPCBs.
The high thermal conductivity of the metal core enables heat dissipation from mounted electronic
components. This makes MCPCBs well suited for thermal management in applications with
high power devices.
This article provides a detailed comparison between the different metal core materials used in PCBs
covering properties, performance, applications, pros/cons and costs.
Aluminum is the most common metal base material used in metal core PCBs due to its combination of good
thermal performance, ease of fabrication and lower cost:
Key attributes:
Applications:
LED lighting
Power converters
Motor drives
Power supplies
Solar inverters
Automotive electronics
Aluminum MCPCBs offer the best balance of thermal performance, manufacturability and cost for most
mid-to-high power electronic circuits.
Copper provides significantly higher thermal conductivity than aluminum. This makes it useful for very
demanding thermal applications:
Properties:
Benefits:
0.25mm to 4mm
0.5mm to 2mm common
Applications:
The excellent thermal performance of copper MCPCB justifies its higher cost in applications where thermal
dissipation is critical for reliability.
Iron alloys containing nickel, cobalt, aluminum etc. offer a lower cost alternative to copper for improved
thermal conductivity over aluminum:
Benefits:
Applications:
LED lighting
Industrial electronics
Telecom systems
Automotive
Iron alloys like iron-nickel-cobalt provide a good compromise between performance and cost for an
intermediate thermal conductivity core material.
The metal is cut into specified panel sizes and thicknesses. Holes are punched for mounting components if
needed. The surfaces are chemically cleaned.
Thin dielectric films like polyimide or FR4 prepregs are laminated onto the metal core under pressure and
temperature. Bonding agents help adhesion.
Circuit Formation
Similar to rigid PCB fabrication, the circuit layers are formed on the dielectric layers using processes like
photolithography, plating and etching.
Component Assembly
Components can be conventionally soldered. For higher heat tolerance, sintering of silver paste or transient
liquid phase bonding is used.
Enclosure Integration
The metal core MCPCB can sometimes directly serve as a housing or enclosure surface for mechanical
stiffness, shielding and heat spreading.<img
src=”https://drive.google.com/uc?export=view&id=1pNpZjav6MG438K0wGShZbZ8eqy3llH-S” alt=”metal
core PCB fabrication” style=”width:500px;height:300px;”>
The specialized materials, processes and integration considerations involved in metal core PCB
manufacturing demand working with an expert supplier.
Aluminum strikes the best balance between cost, performance and manufacturability for most commercial
thermal management PCB applications.
The unmatched thermal performance of copper justifies its usage where removing heat is absolutely critical
for application success.
Iron alloys offer a viable intermediate option where cost or weight are key constraints but thermal
performance must exceed aluminum.
Cost Comparison
Metal core PCBs have higher fabrication cost than FR4 PCBs due to specialized materials,
processes and lower panel utilization.
However, the ability to remove heat from high power components results in overall system cost
savings.
Aluminum core is the most economical metal base material. Iron alloy adds moderate cost
increment over aluminum. Copper core can double the cost over aluminum.
But metal core PCB cost is typically a small fraction of overall system cost for an electronic
product. The thermal and reliability benefits justify the premium.
Cost reduces in high production volumes due to improved material utilization and manufacturing
efficiency.
Some common application areas where metal core PCBs provide benefits include:
LED Lighting
The high power LEDs used require metal core PCBs for heat extraction. Aluminum is widely used but
copper or iron allows driving LEDs at higher currents for greater luminosity.
Power Converters
Switching converters and inverters for power electronics require metal core PCBs to manage substantial heat
dissipation from components like inductors and FETs.
Motor Drives
Servers
Within data centers, high compute density server blades need effective cooling to maintain reliability.
RF Power Amplifiers
High frequency RF amplifiers using GaAs or GaN ICs benefit from the electrical and thermal conductivity
of copper metal core PCBs.
Rugged aluminum or copper core PCBs meet demanding thermal and mechanical performance requirements
in aerospace and military applications.
Conclusion
Metal core PCB technology enables integration of electronic components and systems with higher power
densities by effectively managing dissipated heat. Aluminum, copper and iron alloys provide a range of core
material options to suit different design constraints and applications. Aluminum MCPCBs offer the best
FAQs
What are some key considerations when selecting metal core PCB thickness?
Assembly options:
What alternatives exist to using metal core PCBs for thermal management?
Yes, the metal core must be coated with insulating dielectric films on both sides to avoid electrical shorts.
This adds material cost but allows routing signals like conventional PCBs.
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