Aluminum PCB Flexible and Rigid Custom Manufacturing At One-Stop

"PCBONLINE is an aluminum base PCB manufacturer that adopts automatic manufacturing. Our aluminum PCBs have a thermal conductivity of 1 to 9W/mK. You can have rigid and flex aluminum PCBs manufactured by us."
Aluminum PCB manufacturer

Aluminum PCB Substrate and Dielectric Materials

  • Aluminum PCBs are MCPCBs that use the aluminum substrate. Details of the four types of aluminum PCB substrate materials are below.
  • 6061 is an Al-Mg-Si alloy. It has medium strength and good cutting performance and is suitable for CNC, V-Cut processing. Its drawback is the high price.
  • 5052 is an Al-Mg alloy. It has medium strength and good bending performance and is suitable for punch forming. And it has a fair price.
  • 3003 and 1100 are both pure aluminum. Both have good thermal conductivity and fair machining performance. And both are cheap.

  • Details of the dielectric layer are below.
  • Because both the aluminum substrate and copper circuit layers are conductive, to avoid shorts, a dielectric layer must be in between to insulate them.
  • The dielectric material that PCBONLINE uses is made of a special polymer filled with ceramics. The polymer leads to good dielectric strength, anti-aging, high bonding, and ceramic medium increases thermal conductivity and viscoelasticity. It also resists mechanical and thermal stresses during welding and operation.
  • All double-sided aluminum PCBs require ceramic-filled polymer as the dielectric layer.
2-layer aluminum PCB

Automatic Aluminum PCB Manufacturing at PCBONLINE

  • For quality considerations, the aluminum substrate should not be touched during PCB fabrication and carring the boards.
    From laminates to testing the finished aluminum PCBs, the whole aluminum PCB manufacturing process at PCBONLINE is fully automatic without human intervention, which ensures accuracy and best quality of the aluminum PCBs.
    At PCBONLINE, our production machines include LDI exposure machines, automatic test machines, automatic punching machines, etc. And when we carry the boards, we use an automated guided vehicle (AGV), which increases efficiency and avoids scraches and missing boards, and it matters to quality control.

    Rigid and Flexible Aluminum PCBs

    • From PCBONLINE, you can order both flexible and rigid aluminum PCBs from prototypes to massive production.
    • ● Rigid aluminum PCBs - Most aluminum PCBs are rigid and have good mechanical strength. They can be 1-layer, 2-layer with one component-mounting side, 2-layer with two component-mounting sides, and 4-layer with two component-mounting sides. We can customize the power of the aluminum PCB from 1W/mK to 9W/mK for you.
    • ● Flexible aluminum PCBs - If the aluminum PCB laminate has higher aluminum content, the board can bend, and it can be used for LED lights that can illuminate in all directions. Flex aluminum PCBs have only one layer, the power of 1W, and their surfacer finish can only be OSP. And we suggest 0.5oz copper thickness for them.
    • PCBONLINE is a source factory manufacturer for aluminum PCB fabrication and assembly, and we offer the most affordable prices and considerate one-on-one engineering support throughout your project.

    Aluminum PCB Manufacturing Capabilities

    aluminum PCB structure

    Applications of Aluminum PCBs

    • ● All kinds of LED lights, such as automotive headlights and LED grow lights
    • ● Flexible aluminum PCBs can be used for LED lights that illuminate in all directions
    • ● DC/DC converters
    • ● Industrial controllers
    • ● Rectifiers and motor drive modules
    • ● Solar energy power products
    PCBONLINE's Aluminum PCB Capabilities


    Rigid aluminum PCB: 1, 2, and 4
    Flex aluminum PCB: 1

    Build time

    1 day to 4 weeks

    Aluminum PCB types

    Single-sided, double-sided, flexible aluminum PCB, 1-layer, 2-layer, and 4-layer

    Quality level

    IPC-A-600 Class 3/2/1


    Free sample and $30 per square meter for bulk orders

    Thermal conductivity

    1W/mK to 9W/mK

    Aluminum PCB substrate material

    3003 (pure aluminum)
    5052 (Al-Mg alloy)
    6061 (Al-Mg-Si alloy)
    1100 (pure aluminum)

    Dielectric layer material

    Polymer filled with ceramic

    Copper thickness

    1oz to 4oz (35μm to 140μm)
    (Flex aluminum PCB: 0.5oz to 1oz)

    Manufacturing condition

    Full-line operation production machines and equipment specialized for aluminum PCBs

    Surface finish

    ENIG, OSP, LF HASL, immersion tin, immersion silver, immersion gold
    (Only OSP for flex aluminum PCB)

    Advantages of the One-Stop Aluminum PCB Manufacturer PCBONLINE

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    Fully automatic aluminum PCB manufacturing without human intervention
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    Our engineers make a good balance between thermal resistance and dielectric strength
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    Factory machines, inks, and production lines specially used for aluminum PCB manufacturing
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    We have our aluminum PCB sheet material factory Yugu Chemical Material
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    Reduced aluminum PCB costs due to fully automatic production, own laminate sheets, and PCBA factory
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    Provide aluminum PCBs with low thermal resistance and good thermal conductivity

    Aluminum PCB Certifications

    ISO certified
    IPC certified
    IATF certified
    RoHS certified
    REACH certified
    UL certified

    We are solution experts to Aluminum PCB projects
    Contact our team here

    aluminum core PCB

    Aluminum PCB Example 1

    left go right
    "These are part of the medical-grade aluminum PCBs PCBONLINE fabricated for a client. The pads for keyboard buttons have a hole in the pad center so that gas discharges when a user presses and releases the buttons. The gold surfaces on pads have to be completely flat, without oxide or contamination. We foresaw the details before fabrication, and the order was delivered smoothly."

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