Heavy Copper PCB Projects

Heavy copper PCB stands apart from normal types of PCB due to the unique nature of its raw materials, manufacturing processing and applications.

Compared with standard PCB structures, heavy copper PCB is more than just “extra thickness”.

A specialist in heavy copper PCB manufacturing since 2008, we pride ourselves on tackling the industry’s challenging heavy copper PCB projects. Our expertise spans from robust multilayer power boards to extreme heavy copper designs, specifically engineered for the most demanding industrial and power electronics applications.

Proven Heavy Copper PCB Capability and Examples

12-layer heavy copper PCB

Layer Count: 12 Layers

Inner: 5 oz / Outer: 3 oz copper

Hole Wall Copper: ≥35 µm (1.4 mils)

Min. Trace Width: 10 mil (Inner) / 8 mil (Outer)

Dielectric Thickness: ≥0.08 mm (3.15 mils)

Heavy Copper PCB Projects

6-layer extreme heavy copper PCB

Overall Thickness: < 3.50 mm,

Rated Voltage: ≥ 2 kV

• Stack-up: 6-Layer PCB

• Finished Copper: 30 oz (Inners) / 6 oz (Outers) ,30 oz is extreme heavy copper

• Laminate: Rogers / Arlon base material

• Surface Treatment: Immersion Gold (ENIG)

Heavy Copper PCB Projects

What Makes Thick Copper PCB Different?

The specialized requirement on processing of heavy copper PCB which is characterized with copper thickness from 3OZ to 20OZ.

The thick copper PCBs with reinforced hole plating are designed for high-current applications. Multiple options of copper weight are available, from 18μm,35μm, 55μm and 70μm, 1oz (35μm) is settle to the most popular standard for thermally demanding applications.

KnownPCB’s manufacturing capabilities spans single-sided, double-sided, and multilayer PCB board up to 20 layers. Acting as a robust 'circulatory system' - characterized by high current-carrying capacity, superior heat dissipation, and enhanced structural integrity, heavy copper PCBs are the go-to choice for telecom power supplies, automotive electronics, industrial controls, and renewable energy systems.

Learn about detaild KnownPCB capability of heavy copper.

Challenges in Heavy Copper PCB Fabrication

What are the challenges during heavy copper PCB fabrication or prototyping in KnownPCB workshop?

1. Overcome the challenge of chemical exchange to ensure a uniform result in etching processing

2. Address the bottlenecks of resin flow

3. Mitigate risks on Z-axis expansion stress

What Capabilities Should Buyers Look For in A heavy copper PCB manufacturer?

Now, that begs the question: when hardware engineers or PCB buyers select a heavy copper PCB manufacturer, what specific manufacturing capabilities should be on honing in on?

The following advanced heavy copper capabilities of KnownPCB can be a reference:

• Extreme Copper Weights: It is an industry-leading high-current solution to support both inner and outer layer finished copper thicknesses up to 1050µm (30oz).

• Complex Interconnects: The production capabilities should be included Multilayer Blind & Buried Via structures for high-density, heavy-current designs.

• Advanced Via Filling: Reliable Resin or Conductive Copper Paste Plugging to ensure structural integrity and planar surfaces on thick copper layers.

• High-Reliability Materials: Full support for High-TG laminates to withstand rigorous thermal cycling.

• Enhanced Protection: Precise Solder Mask application with a thickness of up to 50µm for superior insulation.

• Reinforced Plating: Guaranteed Hole Wall Copper thickness of 30µm+, ensuring robust vertical interconnects under high thermal loads.

Work with KnownPCB on Your Heavy Copper PCB Project

If your project requires high current capacity, strong heat dissipation, and reliable interconnection performance, KnownPCB is not a “just-print” service provider, we can support your heavy copper PCB fabrication needs comprehensively. With experience in heavy copper processing, multilayer structures, reinforced plating, and advanced via solutions, we help global customers move from design review to prototyping and volume production with confidence.

Get custom thick copper PCB solutions from KnownPCB for power electronics, industrial control, and high-current applications. We support prototype, low-volume, and multilayer heavy copper PCB manufacturing.