A range of different materials can be used when manufacturing circuit boards. However, they are not all the same. Each material brings something different to the table in terms of performance, tolerances, durability, and more. An informed decision here will maximize performance and durability, reduce weight, and ensure that your design performs to expectations.

Board Types

Circuit boards come in a wide range of types and are classified by component location, stack-up, design, bendability, strength, and electrical functionality. Before choosing a material, make sure you know which classification your design falls into, as this will affect material choices and other decisions.

FR-4

FR-4 is a commonly used material in the design of circuit boards. It is actually made of fiberglass (technically a glass-reinforced epoxy laminate), which means it is relatively lightweight and affordable. For this reason, it is often used in lower-end consumer electronics. The letters FR indicate that this material is also flame retardant, which can be important in applications where heat dispersal is a consideration. It is also known for its high mechanical values, as well as its ability to insulate and perform well even in more humid conditions. However, it may not have the thickness, durability, or capacity for higher-end or higher-performance applications.

When to use it: use FR-4 material in products where cost is a consideration, but you want effective performance across a wide range of applications. Typically, you’ll find FR-4 used in substrate/laminate boards. We recommend it for standard circuit boards.

Rogers Material

The Rogers company also manufactures material for circuit boards. The company offers several options, but one they are best known for is PTFE (Teflon). Teflon costs more than FR-4, but it provides better performance for RF circuit boards because it has a lower signal loss rate. Other advantages include a wide range of dielectric constant values, improved management of heat, and better control over impedance. The trade-off is the higher cost, coupled with slightly more weight.

When to use it: use this material in applications where power management is important, as well as where RF, microwave, or high-performance functionality are necessary. Note that this is a good material for mobile use, too. Typically used in laminate boards, we recommend this option for high frequency, microwave, and high-power situations.

Metal

Metal is an option for the base of circuit boards. So-called “metal core” boards offer greater heft, but also provide better durability and strength. Most are made from aluminum, but alloys exist that can be used instead. Typically, these boards feature the metal base layer, a second layer of conductive dielectric material, and then the final layer of copper on the top. Metal core circuit boards are widely used in solid-state applications, and in use cases where ceramic substrates cannot be used.

When to use it: metal core circuit boards are well-suited for LED applications, but can also be used for other lighting applications, and they also play a role in automotive electronic design.

HDI

HDI, or high-density interconnector, is yet another option for circuit board design. The name says it all – this material offers a high line distribution density and is often used in situations where designers need to reduce weight and size without sacrificing electronic performance. HDI can make use of blind and buried vias, as well as microvias, vias in pad, and through vias from surface to surface.

When to use it: use HDI where density is a consideration, as well as when size and weight are serious concerns. Note that HDI also offers reduced heat transfer included stress.

High Tg

As the temperature of the circuit board and surrounding environment rises, the material of the board’s base layer actually shifts states. The higher the temperature at which the material can remain rigid, the better performing the material will be for board design. Of course, in low-temperature environments, this is not much of a concern. However, with high-temperature environments, the glass-transition temperature (Tg) is important. High Tg materials offer the temperature resistance required for these applications, and they are beginning to be more commonly used across industries.

When to use it: high Tg materials are all about heat control, so this material is well-suited for designs where stability at high temperatures is critically important. We recommend this material for high density needs.

A Note on Solder and Toxicity

Soldering circuit boards can expose you to lead-carrying fumes (lead is sometimes contained within solder). Since any circuit board will require soldering, always solder boards in a well-ventilated area, while wearing appropriate protective gear.

A Full Range of Capabilities for Circuit Boards

At Advanced Circuits, we offer an end-to-end service for your needs in designing and manufacturing circuit boards. From choosing the right material to determining the right number of layers to full PCB assembly, we offer fast turnarounds and affordable pricing. No order is too large or too small. All circuit boards are manufactured within one of our US-based locations, which allows us to manufacture circuit boards for virtually alllayout projects, including DOD contracts.

Layout and Design Help for Circuit Boards

We believe in giving our customers every advantage possible. We understand that designing circuit boards can be incredibly complex, time-consuming, and frustrating. To help ease that burden, we offer free access to PCB Artist — our intuitive, unrestricted PCB design software — to walk you through the entire design process. Create designs of up to 28 layers, import from Eagle, and access a library of over half a million parts all in one place.

Fortunately, there are good options for free PCB design software you can start using. At Advanced Circuits, we provide what we believe to be one of the very best options, and it will not cost you a thing. Let’s take a closer look at the importance of using the right software.

PCB Artist Design Software – Free and Fully Functional

Today, creating and designing printed circuit boards is easier than it has been at any time in the past. One of the big game changers in this area was the creation of design software geared toward printed circuit boards. Quality software can make the process faster because it is possible to look for and find potential mistakes before making a prototype or going into production. It can save time and money.

However, if the software being used is not high quality, it could end up causing problems. Poor software is one of the reasons that some PCB designers still struggle at the design stage. Some of the free PCB design software options that are available are woefully lacking in terms of features and capabilities. Other types of software are very expensive, and not everyone is capable of paying for a pricey piece of software that they might not use very often.

It does not have to be that way. We have an option called PCB Artist. This free PCB design software is a fully-featured option that is sure to please even the most critical designer. The design software has features that are not found even in expensive options on the market today. It is considered professional-grade software and offers free, live technical support. The software includes many features that help to make the design of the PCBs faster and simpler.

Some of the Features of the Free PCB Design Software

The robust library is one of the draws of the software. The library for PCB Artist has more than half a million parts. In addition, you can create up to 28 layers. The software features Gerber format files, and there is a design rule check and report. You can spot errors and correct them before you try to make a prototype of your PCB, which means you will not be wasting your time and money with designs that are not going to work.

The software has a controlled autorouter, component autoplace, individual colored nets options, ratsnest connections optimization, multipage schematics, and a host of other features that help to make it a standout option among the software choices that are available today. When you take the time to compare this software with both free and paid CAD software options on the market, you will see that PCB Artist is head and shoulders above the competition.

One of the best things about this free PCB design software is the fact that it is intuitive and easy to use. While those who have experience in designing printed circuit boards and using other software will not have any trouble, neither will someone who is still learning. It has an easy-to-understand interface. You should be up and running with the system quickly.

In addition, there is a user’s guide that is available for download, tips and tools, and video tutorials. These help to answer questions that people might have about the software and get everyone up to speed. The live tech support is available by email or phone.

You will not need to have a powerful PC to run the software. As long as you have a Pentium processor that is faster than 1.8Ghz and 512MB of RAM, you should be fine. Keep in mind that you will need to have at least 1.26GB of space on your hard drive for the install, but this should not be an issue with most. However, you will want to keep in mind that Linux and MAC OS are not supported at this time.

Creating the PCBs After Designing Them

After you have gone through the process of designing the PCBs and running them through virtual tests to ensure they work, you will want to create a prototype or a production run. Getting a prototype is often a good idea, as it will allow you to see how the PCB works in practice, and you can make any needed changes before going into production.

Once you are certain it is ready, it is time to place your order. Advanced Circuits has decades of experience in this field and is one of the largest manufacturers of PCBs in the United States. The materials used in the construction of the PCBs are always of the highest quality, and you can expect the same quality in the construction of the boards. All of the files for PCBs we make will receive a free engineering file review. This provides you with an additional check to ensure that your circuit boards are ready.

Save Time and Money with Free PCB Design Software

When you choose the software from Advanced Circuits, you will find that you are saving not only on the cost of the software but also saving on wasted time. For those who are using low-quality pieces of software or who do not have software that allows for comprehensive testing, it means mistakes are likely. Those mistakes will cost time and money that most people do not have today. Instead, start using our free PCB design software to get your printed circuit boards ready, so you can have them manufactured.

HDI PCB Fabrication Capabilities

Advanced Circuits operates three state-of-the-art PCB manufacturing facilities in the US with the capabilities, qualifications, certifications, and the expertise to meet the most demanding requirements for HDI PCB fabrication.  Our broad range of printed circuit board fabrication capabilities support the stringent requirements for advanced HDI PCB design in all industries including medical, aerospace, defense, and commercial markets.

Advanced Circuits Supports up to 40 layers boards, laser drilled microvias, stacked microvias, blind vias, buried vias, via-in-pad, laser direct imaging, sequential lamination, .00275″ trace/space, fine pitch down to .3mm, controlled impedance and much more.  Advanced Circuits is able to manufacture HDI PCBs with no minimum order requirements and with flexible turn-time options.  Each design receives a detailed review by our CAM engineers prior to production to ensure a worry-free fabrication process and support team is available 24 hours a day Monday-Friday, even Saturdays until 4pm EST, to assist with your HDI PCB order.

HDI PCB Materials

HDI PCBs use advanced laminate materials that tend to be much thinner than the materials used in more conventional printed circuit boards.  Because HDI PCBs demand an elevated level of precision and accuracy for fabrication and overall performance, specialty materials that meet certain specifications are required.  Advanced Circuits offers a wide range of material options suitable for a variety of HDI PCB specifications sourced from top industry providers such as 3M, Arlon, Bergquist, Isola, Rogers, ITEQ, Taconic, Ventec and others.  You can rely on Advanced Circuits, one of the largest PCB manufacturers in North America, to source the materials for your next HDI PCB design.  Our laminate offerings include:

•  Ultra-Low Loss
• Halogen Free
• High Speed Digital
• High Thermal Reliability
• Lead-Free High Tg
• RoHS Compliant

To download the complete list of Advanced Circuits printed circuit board manufacturing capabilities, material offerings, and certifications, click here (PDF).

Businesses and consumers alike rely on electronic devices for nearly every aspect of day-to-day life. Automobiles are packed full of printed circuit boards (PCBs) for everything from lighting and entertainment to sensors that control the behavior of critical mechanical functions. Computers, tablets, smartphones, and even many toys enjoyed by children incorporate electronics and PCBs for their sophisticated functionality.

PCB designers today are challenged to create reliable boards that perform increasingly complex functions while controlling costs and shrinking in dimension. This is especially critical in applications such as smartphones, drones, and other applications where weight is a critical consideration in the PCB characteristics.

Gold is an important element in the design of printed circuit boards, and looking closely at most PCBs will reveal that the ‘fingers’ on the board include metal contacts fabricated from gold. These fingers are typically multi-layered metals that may include materials such as tin-lead, cobalt, or nickel, plated with a final layer of gold. These gold contacts are critical to the functionality of the resulting PCB, establishing the connection with the product containing the board.

Why Use Gold?

Attributes of gold make it an excellent choice for use in PCB fabrication. Edge connectors plated with gold provide a consistent surface finish for applications that are subjected to high-wear such as board insertion edge points. Hardened gold presents a stable surface quite resistant to wear from such repeated activity.

By its very nature, gold is ideally suited for electronics applications:

• It is easily formed and manipulated for connectors, wires, and relay contacts
• Gold conducts electricity very efficiently (an obvious requirement for PCB applications)
• It can carry small amounts of current, essential for today’s electronic devices
• Other metals can be alloyed with gold such as nickel or cobalt
• It does not tarnish or corrode, making it a reliable connection medium
• Melting and reclaiming gold for reuse is a relatively simple process
• Only silver and copper provide higher conductivity properties, but each of them are prone to corrosion, generating current resistance
• Even thin applications of gold can provide reliable and stable contacts with low resistance
• Gold connections can tolerate high temperatures
• Variations in thickness can be utilized to meet the requirements of specific applications

Nearly every electronic device contains some level of gold in its construction including televisions, smartphones, computers, GPS units, and even wearable technology. Computers are natural applications for PCBs containing gold and other gold elements due to the requirement for reliable, high-speed transfer of digital signals more suited to gold than any other metal.

Gold is unrivaled in its for use in applications that include requirements for low voltage and low resistance, making it ideal for PCB contacts and other electronic applications. Usage of gold in manufacturing for electronic devices has now far surpassed the consumption of the precious metal in jewelry fabrication.

Another contribution that gold has made for technology is in the aerospace industry. With the long life expectancy and reliability of gold connections and PCBs integrated into spacecraft and satellites, gold is the natural choice for critical components.

Other Considerations for Gold in PCBs

Of course there are drawbacks to using gold in PCBs:

• Price – as a precious metal there are limited resources of gold, making it an expensive material for use in millions of electronic devices.
• Lost resources – one example is the use of gold in such modern devices as smartphones. The majority of smartphones are not recycled, making careless discarding of the phones a permanent loss of a minute quantity of gold. Although small amounts, the huge volume of discarded devices adds up to a considerable quantity of unrecycled gold.
• Gold applied by itself can be susceptible to wear and smearing under repeated or high-pressure installation/sliding conditions. This makes application over a compatible under-layer utilizing harder materials most effective. Another consideration for PCB use is the combination of gold with another metal such as nickel or cobalt to form an alloy referred to as ‘hard gold’.
• The US Environmental Protection Agency (EPA) has reported that electronic waste is growing at a rate faster than nearly every other waste commodity. This includes not only the loss of gold, but other precious metals and possible toxic materials, as well.

PCB manufacturers must weigh their use of gold in PCB fabrication carefully: applying too thin a layer of the metal may result in boards that fail or are not consistent in performance. Utilizing extra thickness becomes wasteful and expensive for manufacturing.

There are currently very limited choices or alternatives available to PCB manufactures that live up to the capabilities and inherent attributes of gold or gold alloys. Even with the high value of this precious metal it will undoubtedly remain the material of choice for PCB construction.