Aluminium PCB manufacturing — matched to the right manufacturer.
Upload your Gerber files for a free DFM check. We find the manufacturer in our network with the right experience in metal core boards for LED and power electronics.
The technology
What is an aluminium PCB?
An aluminium PCB (also written aluminum PCB) is the most common type of metal core PCB, also called an insulated metal substrate (IMS). It has three main layers: an aluminium base that spreads and conducts heat, a thin thermally conductive dielectric that insulates the circuit electrically from the base, and a copper circuit layer on top. Compared with a standard FR-4 board, heat from components moves through the thin dielectric into the metal base far more effectively, which keeps junction temperatures down and extends component life. The dielectric is the critical material choice: it sets both the thermal performance and the isolation voltage.
Our network includes manufacturers experienced in aluminium and other metal core boards.
Applications
When to choose an aluminium PCB
Choose an aluminium PCB when heat, not routing density, is the main design constraint. Typical applications:
- High-power LED modules, street lighting and LED luminaires.
- Power conversion, such as power supplies, DC/DC converters and inverters.
- Motor drives and motor controllers.
- Automotive lighting, including headlamps and rear lights.
- Solid-state relays and other power switching circuits.
- Designs where a metal base also serves as a mechanical mounting plate or heat spreader.
Design for manufacturing
Aluminium PCB design tips
- Specify the dielectric by thermal conductivity and breakdown voltage, not only by board thickness, because the dielectric determines thermal and isolation performance.
- Plan for a single-sided design where possible; most aluminium boards are single-sided, and double-sided or multilayer metal core boards are possible but considerably more complex.
- Choose the copper weight for the current the circuit carries, and use wide traces and copper areas to spread heat.
- Use a white solder mask for LED boards to improve reflectivity, and check its resistance to discolouration.
- Plan the outline and panel separation for a metal base; V-scoring and routing behave differently in aluminium than in FR-4.
- Keep sufficient clearance between copper and the board edge to maintain isolation to the metal base.
Our free DFM check and the manufacturer's own engineering review help catch issues like these before production.
Checklist
What to send for an aluminium PCB quote
- Gerber files and board outline
- Base metal: aluminium or copper core
- Base thickness
- Dielectric thermal conductivity and isolation (breakdown voltage) requirement
- Copper weight
- Solder mask colour
- Surface finish
- Quantity (prototype and expected production volume)
Upload your Gerber files. Get a free PCB quote.
We check your files for free and compare manufacturers in our network to find the best match. No obligation.
- Free quote
- Free DFM check
- 12 vetted manufacturers
What happens when you upload?
One of our engineers checks your Gerber files with our in-house DFM tool and emails you any findings within 72 hours. We then compare manufacturers in our network that fit your spec and send you the quote from the best match. Files are shared only with manufacturers we select, under NDA.
- Upload your Gerber files
- We check your files
- We compare manufacturers
- You get your quote
Free for you — you order directly from the manufacturer.
Common questions
FAQ about aluminium PCBs
What is an aluminium PCB?
An aluminium PCB is a metal core printed circuit board with an aluminium base, a thin thermally conductive dielectric layer and a copper circuit layer. The aluminium base draws heat away from components much more effectively than FR-4. Aluminium PCBs are widely used for high-power LEDs, power supplies and motor drives, where thermal management is the main design constraint.
What is the difference between aluminium and copper core PCBs?
Both are metal core PCBs, but a copper core conducts heat considerably better than aluminium and is chosen for the highest power densities. Copper is also heavier, harder to machine and more expensive. Aluminium offers a good balance of thermal performance, weight and cost, which is why it is the most common metal core material for LED and power boards. In practice, the dielectric layer usually limits thermal performance more than the choice of base metal.
What is an aluminium nitride PCB?
An aluminium nitride (AlN) PCB is a ceramic circuit board, not a metal core board. Aluminium nitride is a ceramic with high thermal conductivity and excellent electrical insulation, and is used in high-power modules, laser diodes and RF power devices. It is more costly and brittle than an aluminium PCB and is produced with different processes.
Can aluminium PCBs be multilayer?
Yes, but multilayer aluminium PCBs are uncommon. Most aluminium boards are single-sided, with one copper layer on the dielectric. Double-sided and multilayer metal core constructions exist, but they need extra insulation around plated holes through the metal base, which adds cost and complexity. If you need more routing layers, consider an FR-4 board bonded to a metal heat spreader.
Specialist boards