High-Frequency PCB Manufacturing at PCBAIR

High-frequency PCBs are similar in design to multilayer PCBs but require materials with good dielectric properties. These materials include Rogers, FR4, Teflon, ceramic, and polyimide, with silicon dioxide used as a filler. The choice of materials depends on the specific application. For instance, when operating at frequencies above 10 GHz, Teflon is often the preferred material.

All high-frequency PCBs from PCBAIR include a ground plane, which is important for high-speed applications. This feature helps reduce electromagnetic emissions and maintain signal quality. We provide controlled impedance traces to ensure they align well with both the power source and the load.

Skin effect and crosstalk are common challenges in high-speed PCBs. Crosstalk occurs when components couple with each other, causing interference. To prevent this, we reduce the distance between the plane and the trace layer. Skin effect, which arises due to increased resistance, can lead to higher temperatures. Our approach involves optimizing the trace length and width to manage heat effectively.

Our engineers at PCBAIR adjust trace width based on different copper thicknesses and measure the etched copper thickness to keep it within a tolerance range of ±0.02 mm, or even ±0.015 mm for higher precision. After creating the film, we thoroughly inspect it to ensure no defects like pinholes or gaps are present. Even minor flaws can affect transmission, and we eliminate these to maintain quality.

For chemical copper sinking, we use the plasma method—the most challenging step in high-frequency PCB manufacturing. Each hole must be fully plated with copper, leaving no gaps. We inject gases such as carbon tetrafluoride (CF₄), argon, nitrogen, and oxygen between high-pressure electrodes under vacuum, with the PCB placed between them. This creates plasma that removes drilling debris and ensures clean holes.

We also maintain strict control over the solder mask thickness, as even slight variations can result in disqualification. During the final manufacturing stage, a destructive test is performed using thermal shock at 288°C for 10 seconds, repeated up to three times, to confirm the hole walls remain intact.

PCB Laminate Materials Suppliers

To ensure your PCBs are reliable and perform well, we use high-quality laminate materials. We have built strong partnerships with top suppliers in the industry, including trusted brands like Rogers, Panasonic, Dupont, Arlon, Taconic, Nelco, Isola, Teflon, and more. This means you receive the best materials tailored to your project needs, providing the performance and durability you expect.

High-Frequency PCB Capabilities

By reviewing the following high-frequency PCB capabilities table, you can briefly understand what we can do.

Need Help With Your Project?

Please send us a message, and our high-frequency PCB manufacturing capabilities can help you complete your next project.