Aluminum Core PCB Manufacturing

Custom Aluminum PCB Manufacturing for Heat-Critical Electronics

Metal-core PCB manufacturing for LED lighting, power modules, automotive lamps, and industrial electronics.
We manufacture custom aluminum PCBs for LED lighting, power conversion, automotive, and industrial control applications. Send your Gerber files, layer stackup, quantity, and thermal requirements for a manufacturability review and quote.

  • 2-3 Days Prototype

  • 1-15 W/m.K Thermal

  • 0.4-3.2 mm Thickness

Get You Quote!

What Are Aluminum PCBs?

Aluminum PCBs are metal-core printed circuit boards that use an aluminum substrate instead of traditional FR4. The metal base acts as a heat sink, transferring heat away from high-power components to ensure stable performance and longer product life.

They are widely used in LED lighting, power electronics, industrial control, and automotive applications where thermal management and reliability are critical.

Cross‑sectional diagram of a heat-dissipating stack: copper circuit layer on top, then a thermal dielectric layer, aluminum base layer, with orange arrows showing heat flowing downward.

Advantages of Aluminum PCBs

Efficient Heat Dissipation

Aluminum base rapidly transfers heat away from components, reducing operating temperature and improving system stability.

High Durability

Excellent thermal cycling resistance and mechanical strength ensure long-term reliability in demanding environments.

Lightweight Metal Core

Aluminum provides strong thermal performance with reduced weight, ideal for weight-sensitive applications.

Cost-Effective for Volume

Lower thermal management costs and improved product life help reduce total cost of ownership in mass production.

Our Aluminum PCB Manufacturing Capabilities

From prototype builds to volume production, our aluminum core PCB process supports thermal performance, dimensional control, and assembly-ready finishes.

Feature Capability
Core Material Aluminum, Copper-Aluminum
Stack-Up Types Single-sided, double-layer, multilayer, thermoelectric separation
Board Thickness 0.4 mm to 3.2 mm standard
Dielectric Thermal Conductivity FR4, 1, 2, 3 W/m.K; custom up to 15 W/m.K
Copper Thickness 0.33 oz to 10 oz
Surface Finish ENIG, ENEPIG, OSP, Hard Gold, Immersion Silver
Min Trace / Space 2.5 mil or 4 mil options
Lead Time 2-3 days prototype

Free DFM Check

Get manufacturability feedback early to reduce risks and costs.

AOI + Flying Probe

100% inspection for solder quality and electrical reliability.

IPC Class 2 / Custom Grade

Built to meet IPC standards and your product-level requirements.

Close-up of a metal electronic circuit board with a circular hole and tiny surface-mount pads.

Specification of Aluminum Based Copper -Clad Laminate

Part Number AL-01-B10 AL-01-B15 AL-01-B30 AL-01-B20 GL12, GL22
Vendor BOYU BOYU BOYU BOYU GDM
Thermal Conductivity
(W/m·k)		 1.0 1.5 3.0 2.0 1.0 < λ≤1.5
Peel Strength
(Lb/in)		 ≥8 ≥8 ≥8 ≥8 ≥6
Breakdown Voltage
(AC/KV)		 5.0 5.0 4.0 for 75um dielectric thickness
4.5 for 100um dielectric thickness
6.0 for 125um dielectric thickness		 1.5 for 60um dielectric thickness
3.5 for 75um dielectric thickness
4.0 for 100um dielectric thickness
5.0 for 125um dielectric thickness		 ≥2
Tg (°C) 110 110 150 130 AABUS
Td (°C) 380 380 380 380 AABUS
Dk (@1MHz) 4.8 4.8 4.8 4.8 AABUS
Df (@1MHz) ≤0.02 ≤0.02 ≤0.02 ≤0.02 AABUS
MOT 130°C 130°C 130°C 130°C –

Types of Aluminum PCBs We Manufacture

Choose the right metal-core structure for thermal path, component layout, and production cost.

Single-Layer, Single-Sided

  • Components on one side
  • Simple construction, cost-effective
  • Ideal for LED lighting and power modules

Two-Layer, Single-Sided

two-layer-single-sided
  • Two copper layers on the component side
  • Lower thermal resistance
  • Suitable for high-power, compact designs

Two-Layer, Dual-Sided

two-layer-dual-sided
  • Components on both sides
  • Plated through-holes are isolated
  • Ideal for control and power circuits

Four-Layer, Dual-Sided

four-layer-dual-sided
  • Multilayer structure for complex routing
  • Better EMI control and current distribution
  • Designed for high-performance power systems

Production Challenges & Solutions

1. Via Isolation

Plated through-holes can create a direct path to the aluminum core, leading to electrical leakage.
We use resin plugging and dielectric inserts to fully isolate PTHs from the aluminum core, ensuring electrical safety and long-term reliability.

2. Copper + Dielectric Control

Unbalanced copper thickness or dielectric selection can increase thermal resistance and reduce heat dissipation.
We control copper weight, dielectric thickness, and material parameters during lamination to minimize thermal resistance and maintain mechanical strength.

3. Routing & Drilling

Aluminum cores accelerate tool wear and can cause burrs or delamination during mechanical processing.
We use carbide or diamond tooling with optimized feeds and speeds, plus backing boards and fixture support for clean routing, drilling, and milling.

Need PCB Manufacturing or Assembly?

Get a free quote within 24 hours. We specialize in prototype-to-production PCB/PCBA for hardware teams worldwide.

Get a Free Quote

Applications for Aluminum PCBs

application-led-lighting

LED Lighting Systems

LED panels, headlamps, luminaires and signage boards requiring excellent heat dissipation.

Power electronics circuit board with transformer, coils, capacitors, and heatsinks on a metal baseplate in a lab setting

Power Supply Modules

DC-DC converters, voltage regulators and inverters that demand stable thermal performance.

application-automotive-electronics

Automotive Electronics

Lighting boards, motor drives and ECU modules built for high reliability and wide temperature range.

application-industrial-control

Industrial Control

Control boards and instrumentation used in high-heat, continuous operation environments.

How to Order Your Aluminum PCB

Online Quote
Get an instant quote by providing your details and specifications.
Instant
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2
Order Review
Our team carefully reviews your order to ensure accuracy.
Quality Check
Payment
Secure your order with a hassle-free payment process.
Secure
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Production
We begin crafting your order with precision and efficiency.
In Progress
Delivery
Your order is shipped swiftly using reliable carriers.
Fast Shipping
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Confirm Received
Receive your order and confirm everything meets your expectations.
Complete

Frequently Asked Questions

Q: When should I choose aluminum PCB instead of FR4?

A: Choose aluminum PCB when your design has high thermal load, such as LEDs, power conversion, automotive lighting, or industrial electronics where heat dissipation affects reliability.

Q: Can you manufacture multilayer aluminum PCBs?

A: Yes. We support single-sided, double-layer, multilayer, and thermoelectric separation structures depending on circuit complexity and thermal requirements.

Q: What files are needed for quotation?

A: Please provide Gerber files, drill files, board specifications, quantity, surface finish, solder mask color, and any special stack-up or thermal conductivity requirements.

Q: What surface finishes are available?

A: Available finishes include ENIG, ENEPIG, OSP, Hard Gold, Immersion Silver, HASL, and Lead-Free HASL depending on the application and assembly requirements.