2 Layer Aluminum PCB Production Record #ALU-20250828-0086

Five 2-layer aluminum boards were produced for this order, each measuring 56 × 71.9 mm with 1.6 mm overall thickness, 1 oz copper foil, and 2.0 W/mK thermal conductivity. The design called for 10/10 mil trace spacing, minimum 1.5 mm holes, white solder mask, and black silkscreen. These parameters, combined with an AC 2500 V withstand rating, required careful selection of the aluminum base and dielectric layer to balance heat transfer with electrical isolation.

Manufacturing began with metal-base preparation and circuit imaging followed by controlled etching to preserve the substrate integrity. Thermal insulation lamination was performed under strict temperature and pressure settings to achieve uniform bonding without compromising the 2.0 W thermal path. White solder mask was applied and cured, then molten solder coating and hot air leveling produced a consistent HASL Lead Free finish. Final electrical testing verified isolation and continuity on all five boards.

Heat dissipation characteristics were monitored throughout to maintain performance within specification. The complete run was delivered after 12.9 days, providing the customer with reliable aluminum PCBs that meet both thermal management and voltage requirements without deviation from the stated design.