Heavy Copper PCB Manufacturing — High-Current & Power-Handling PCBs
Reliable heavy copper PCB manufacturing with 2–6 oz copper, enhanced thermal performance, stable plating, and high-current capability for power electronics and industrial-grade applications.
Heavy copper PCB manufacturing enables high-current, high-reliability circuit structures for automotive, industrial and power electronics. These boards provide enhanced thermal performance, strong mechanical stability and superior copper bonding to support continuous high-current operation.
LinkPCBA provides stable, mass-production-ready heavy copper PCB solutions through audited partner factories combined with engineering validation and full QA inspection.
Customer Challenge — High Current, Heat & Reliability
A global industrial electronics customer required a 4 oz copper PCB for a power converter module. Key challenges included:
- Carrying high continuous and peak current
- Reducing heat buildup under load
- Maintaining copper plating reliability in thick layers
- Ensuring stable mechanical strength for screw terminals
- Preventing delamination under thermal cycling
- Guaranteeing consistent quality across large volume production
Standard 1 oz or 2 oz PCBs cannot meet these requirements—heavy copper design is necessary.
Engineering Solutions — High Current & Thermal Reliability
To solve the customer’s RF challenges, LinkPCBA implemented a complete high-frequency manufacturing workflow:
Thick Copper Plating
- 2–6 oz finished copper thickness
- Uniform plating distribution for high reliability
- Reinforced corners and pads for terminal connectors
Thermal & Current Path Optimization
- Wide copper pours and reinforced traces
- Multiple copper layers for high-current stacking
- Controlled heat-spreading design for power components
Advanced Via Structures
- Stacked or filled vias for current paths
- Through-hole plating with stable aspect ratio
- Copper-filled vias optional for extreme current needs
High-Reliability Lamination
- High-TG FR4 core
- Low CTE materials for thermal stability
- Vacuum lamination to reduce voids
Mechanical Reliability
- High peel strength between copper and dielectric
- Strong pad adhesion for high-torque connections
- Flatness control for module assembly
Quality & Reliability Verification
- AOI for all layers
- X-ray for via and copper balance check
- Flying-probe electrical testing
- Thermal stress and reliability testing
Summary:Engineered for stable high-current flow, excellent heat dissipation and long-term reliability for power electronics.
Performance Validation — Proven Heavy Copper PCB Results
After full validation:
- Copper thickness: 2–6 oz
- Peel strength: ≥1.2 kgf/cm
- Impedance variation: ±10% (power circuits)
- Thermal shock: Passed 100+ cycles
- Flatness: <0.20 mm
- Current carrying capability: consistent across batches
These results confirm suitability for high-power industrial and automotive systems.
PCB Manufacturing Capabilities
- 1
- 2
- 3
Applications of Heavy Copper PCBs
Power Supply Units (PSU)
DC-DC Converters
Industrial Motor Drivers & Controllers
Automotive Power Modules
Solar Inverters & Energy Systems
High-Current Battery Management Systems (BMS)
Communication Power Boards
Why OEM & ODM Clients Choose LinkPCBA for Heavy Copper PCBs
- Advanced heavy-copper PCB fabrication capability supporting 2–6 oz copper thickness and high-current designs
- Engineering-driven support for current-path optimization, thermal management and power-layer stack-up planning
- Comprehensive QA workflow, including AOI, X-ray, flying-probe testing and thermal cycling validation
- Reliable high-current performance for power modules, automotive systems and industrial applications
- Certified quality system ensuring consistent manufacturing output and long-term durability
- Fast engineering response with 24h DFM review and quotation for heavy-copper PCB projects
FAQ — Heavy Copper PCB
We support 2–6 oz finished copper thickness for heavy copper applications.
Power modules, motor drivers, automotive power systems, BMS, communication power boards and industrial power supplies.
High-TG FR4 and low-CTE laminates to handle high current and thermal stress.
Yes. Copper-filled, resin-filled and stacked vias are available depending on design needs.
6/6 mil is standard for 2–6 oz copper.
Prototype: 5–10 days
Mass production: 10–15 days
Start Your Heavy Copper PCB Project
Get a free DFM review and 24h quotation for your power electronics design.
⭐ Verified by LinkPCBA Engineering Department — Updated April 2025