Powering Performance: Types and Applications of Thick Copper PCBs

As electronic devices continue to advance in performance and complexity, the need for PCBs capable of safely handling high currents is growing steadily. One notable solution is the Thick Copper PCB.

A Thick Copper PCB is a specialized board designed to deliver high current capacity, superior heat dissipation, and exceptional mechanical strength by significantly increasing the copper foil thickness compared to standard PCBs.

What is a Thick Copper PCB?

• Standard printed circuit boards typically use copper foil with a thickness of 18 µm (0.5 oz) to 35 µm (1 oz).
• Thick Copper PCBs are defined as boards with copper thickness of 70 µm (2 oz) or more
• Depending on the application, thickness can range from 105 µm (3 oz) to 210 µm (6 oz), and even ultra-thick copper boards exceeding 400 µm (12 oz).
• The thicker the copper, the higher the current capacity. However, increased thickness makes etching and processing more challenging and raises manufacturing costs. Selecting the optimal thickness for the application is essential.

These factors are closely interrelated and must be considered as part of a complete system. Achieving the desired electrical performance, such as impedance, requires holistic optimization.

Types of Thick Copper PCBs

Thick Copper PCBs are categorized based on their design and application:

Single-Sided Thick Copper PCB

• Copper foil is thickened on only one side.
• Commonly used for power lines and simple high-current circuits.

Double-Sided Thick Copper PCB

• Thick copper layers are applied to both sides of the board.
• Ideal for power circuits that need efficient high-current transmission.

Multilayer Thick Copper PCB

• Thick copper layers can also be integrated into inner layers.
• Used in power modules requiring both high-current paths and control signals.

Hybrid PCB

• Only selected layers use thick copper, while others maintain standard copper thickness.
• Balances high-current capability with cost efficiency.

Application Examples of Thick Copper PCBs

Thick Copper PCBs are widely used in applications that demand high current capacity, voltage resistance, and efficient heat dissipation, including:

• Power Circuits: DC/DC converters, inverters, power distribution boards
• Power Electronics: Motor control boards, power modules, industrial equipment
• Automotive (EV/HEV): Battery management systems (BMS), electric power steering, onboard chargers
• Renewable Energy: Solar inverters, wind power control systems
• LED Lighting: High-current LED drivers and lighting boards requiring effective thermal management

In these applications, the high current capacity and heat dissipation properties of thick copper PCBs directly contribute to stable operation and longer equipment life.

Summary

Thick Copper PCBs are designed to meet the growing need for high current capacity and efficient heat dissipation, which standard PCBs cannot provide.

• Types: Single-sided / Double-sided / Multilayer / Hybrid
• Applications: Power circuits, power electronics, automotive, renewable energy, LED lighting

As EV adoption and renewable energy systems expand, demand for Thick Copper PCBs will continue to rise. In PCB design, selecting the optimal copper thickness is critical to balance performance, manufacturability, and cost.

Need a PCB That Can Handle Extreme Currents and Heat? Let’s Build It Together.

If you’re unsure how to choose the right copper thickness, layer configuration, or design approach for high-current applications, we’ve got you covered.
Upload your files here and let us optimize your stack-up for maximum current capacity, thermal performance, and reliability.
Want to learn more? Download our PCB Design Guide for practical insights on material selection, cost considerations, and advanced manufacturing techniques.