Menu
As electronic systems operate with higher current requirements, PCB design becomes an important consideration in electrical performance, power distribution and thermal management.
Copper thickness, conductor geometry, temperature rise and PCB stack-up are key factors engineers must evaluate when developing printed circuit boards for high-current applications.
Sunshine Global Circuits (SGC) offers Heavy Copper PCB manufacturing solutions for applications requiring thicker copper conductors and customised multilayer board construction.
Heavy Copper PCB technology can be considered where current-carrying requirements, available routing space and thermal conditions influence PCB design decisions.
Sunshine’s portfolio includes Heavy Copper PCB examples for power electronics and motor applications, including a 26-layer Axial-Flux Motor PCB featuring 4 oz copper construction.
1. Heavy Copper Construction
Heavy Copper PCBs incorporate thicker copper conductors to accommodate application-specific current requirements. Copper thickness should be evaluated alongside conductor dimensions and allowable temperature rise.
2. Copper Thickness & Trace Geometry
Copper weight, trace width and conductor geometry influence electrical resistance and current-carrying capacity. These factors require careful consideration when routing higher currents within available PCB space.
3. Thermal Design Considerations
Copper layers contribute to heat conduction within a PCB. Actual thermal performance depends on conductor geometry, stack-up, heat sources and operating conditions.
4. Customised Multilayer PCB Construction
Heavy Copper PCB designs may require specialised layer arrangements and dielectric separation to accommodate electrical, mechanical and manufacturing requirements.
5. Specialised PCB Manufacturing Processes
Manufacturing Heavy Copper PCBs requires careful control of etching, lamination, drilling and solder-mask processes.
Sunshine’s manufacturing capabilities support customised Heavy Copper PCB constructions for different engineering requirements.
Sunshine Global Circuits’ Heavy Copper PCB technology is relevant to various high-current electronic applications.
1. Axial-Flux Motors & PCB Stators
Axial-flux motor designs can incorporate PCB-based stator structures that require careful consideration of conductor geometry, copper thickness and multilayer construction.
Sunshine’s portfolio includes a documented 26-layer, 4 oz Heavy Copper Axial-Flux Motor PCB example.
2. Industrial Motor Drives
Industrial motor drive systems may require specialised PCB conductor arrangements for electrical power handling and thermal design considerations.
Sunshine’s Heavy Copper PCB portfolio includes examples associated with industrial motor and drive applications.
3. Automotive Powertrain Systems
Automotive powertrain electronics involve application-specific electrical, mechanical and thermal design requirements.
Sunshine identifies powertrain systems among the application areas for its Heavy Copper PCB technology.
4. Power Conversion & DC/DC Converters
Power conversion systems require PCB designs that account for conductor current, copper geometry, electrical spacing and temperature rise.
Heavy Copper PCB technology may be evaluated for appropriate power conversion applications according to the required electrical and manufacturing specifications.
Developing a PCB design for a high-current application?
Connect with iConnexion Asia to discuss your project requirements, including copper thickness, layer count, conductor geometry, PCB stack-up and manufacturing considerations.
Heavy Copper PCB technology provides manufacturing options for applications requiring thicker copper conductors and customised multilayer PCB designs.
Sunshine Global Circuits’ portfolio includes Heavy Copper PCB solutions for high-current electronics, power conversion and motor-related applications, including its documented 26-layer Axial-Flux Motor PCB example.
By evaluating copper thickness, conductor geometry, PCB construction and thermal requirements, engineers can identify appropriate PCB manufacturing considerations for their intended designs.
Explore Sunshine PCB solutions through iConnexion to discuss your next PCB project’s technical and manufacturing requirements.
