2 Layer Aluminum PCB Production Record #ALU-20250924-0084

This aluminum printed circuit board order consisted of 100 single boards with 2 layers, 2oz copper, and 3.0W thermal conductivity. At 2mm thick and sized 105 x 59.5mm, the design called for careful metal base preparation and thermal insulation lamination to preserve the dielectric properties essential for heat management. We performed circuit imaging and etching, followed by thick copper electroplating and controlled etching to realize the 10/10mil minimum features accurately.

Matte black solder mask was applied prior to the lead-free HASL surface finish, which utilized molten solder coating and hot air leveling suited to the aluminum substrate. No silkscreen was required, simplifying the mask process while maintaining full coverage. Production included specific heat dissipation control steps along with high voltage and electrical testing to ensure all boards satisfied the AC2500V withstand requirement and overall performance criteria.

The completed boards demonstrated consistent thermal and electrical characteristics, reflecting the process controls applied throughout the 14-day manufacturing cycle.