Aluminium PCBs / Metal-Core PCBs
Efficient, high-thermal-performance PCBs for LEDs, power electronics & heat-sensitive applications.
Aluminium PCBs (also called IMS — Insulated Metal Substrate boards or metal-core PCBs) offer superior heat dissipation compared to standard FR4 boards. By bonding a thin dielectric layer to a metal core (usually aluminium), they efficiently transfer heat away from critical components. This makes them ideal for LED lighting, power modules, motor drives, and high-power circuits.
At Tate Circuits, we manufacture aluminium PCBs in our Shenzhen factory under ISO / UL quality standards — giving UK and global buyers both performance and reliability. There is no minimum order quantity for aluminium PCB manufacture. We can supply from 1-off PCB prototypes to volume PCB production runs.
Upload your Gerber files now to request a quotation for aluminium PCBs, or talk to our engineers about your thermal design.
Why Choose Aluminium / IMS PCBs?
Aluminium PCBs (also known as IMS — Insulated Metal Substrate boards) are becoming increasingly popular as electronic devices become smaller, more powerful, and more heat-sensitive. Choosing aluminium over a standard FR4 board brings multiple performance and reliability advantages:
1. Superior thermal management
Heat is one of the biggest causes of electronic component failure. The aluminium core acts as an integrated heat sink, spreading heat evenly across the board and away from sensitive components. This reduces junction temperatures, prevents hotspots, and allows higher power densities without the need for bulky external cooling solutions.
2. Longer lifespan under stress
Aluminium PCBs are far more resistant to thermal cycling — the repeated heating and cooling that can cause solder joints to crack and PCBs to delaminate over time. This makes them ideal for products that operate continuously or in harsh environments, such as industrial lighting, automotive modules, and motor drives. The result is improved reliability and longer service life.
3. High design flexibility
Despite their metal base, aluminium PCBs still support standard PCB technologies such as plated through-holes, solder mask, silkscreen legends, fiducials, and surface finishes (HASL, ENIG, OSP, etc.). Designers do not need to compromise on layout creativity or functionality, and hybrid designs (aluminium with FR4) are also possible for more complex applications.
4. Cost-effective for production
Thanks to advances in material technology and automated production, aluminium PCBs are no longer a premium-only option. For many applications, their cost is now close to that of traditional FR4 — especially at medium to high volumes where economies of scale apply. Considering the reduced need for additional heat sinks or thermal management components, total system cost is often lower with aluminium.
5. Broad industry adoption
Aluminium PCBs are already trusted across a wide range of industries where heat dissipation is critical:
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LED lighting: Street lights, automotive headlights, signage, architectural lighting.
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Automotive & EVs: Power converters, charging modules, battery management systems.
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Industrial power & control: Motor drives, power regulators, UPS systems.
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RF and telecoms: High-frequency modules where heat and signal stability must be controlled.
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Consumer electronics: Compact devices where small size and reliability under load are essential.
By combining thermal efficiency, reliability, and cost competitiveness, aluminium PCBs have become a go-to choice for engineers designing high-performance, heat-sensitive products.
Aluminium PCBs vs FR4 PCBs — What’s the Difference?
When deciding between aluminium PCBs and traditional FR4 circuit boards, the right choice depends on your application. Here’s how they compare across the most important factors:
1. Thermal performance
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Aluminium PCBs: Excellent heat dissipation thanks to the metal core acting as an integrated heat sink. Ideal for high-power LEDs, automotive modules, and power electronics.
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FR4 PCBs: Poor thermal conductivity. Additional heat sinks or cooling components are usually required for demanding applications.
2. Mechanical strength & durability
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Aluminium: Stronger and more rigid, making boards more resistant to mechanical stress, vibration, and thermal cycling.
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FR4: More flexible but less durable in high-temperature environments. Risk of warping or delamination under thermal stress.
3. Weight & size reduction
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Aluminium: Eliminates the need for external heat sinks, reducing both overall size and weight of assemblies.
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FR4: Requires additional cooling solutions, which increase bulk and add weight.
4. Cost considerations
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Aluminium: Slightly more expensive per board than FR4, but total system cost can be lower because of reduced cooling requirements and improved reliability. Costs are also falling as aluminium PCBs are produced in higher volumes.
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FR4: Lower initial board cost, but often requires extra components (heat sinks, fans, larger housings), increasing overall expense.
5. Typical applications
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Aluminium PCBs: LED lighting, automotive electronics, power converters, industrial control, RF amplifiers.
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FR4 PCBs: General-purpose electronics, consumer products, lower-power circuits, applications where heat is not a critical issue.
Key takeaway
If your design involves heat-sensitive components or requires high reliability under continuous load, aluminium PCBs are the better long-term choice. FR4 remains cost-effective for low-power, general-purpose applications, but aluminium delivers superior thermal performance and product lifespan where it matters most.
Our Aluminium / Metal-Core PCB Capabilities
At Tate Circuits, our facilities are fully equipped to support a broad range of specifications for aluminium / metal-backed PCBs:
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Layers: 1–4 layers typically (single-sided, double-sided, plus optional copper traces).
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Board size: Up to 600 × 600 mm (or custom sizes upon request).
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Copper thickness: 0.5 oz – 3 oz (standard) or heavier on demand.
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Dielectric / insulation layer: High-performance thermal dielectrics with high thermal conductivity.
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Materials: Aluminium cores (standard), optional copper cores, hybrid substrates.
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Vias & routing: Standard via drilling, plated through-holes, mechanical routing.
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Surface finishes: HASL (lead-free), ENIG, OSP, immersion silver, etc.
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Mask & legend options: Choice of solder mask colours, silkscreen legend, fiducials, mechanical cut-outs.
Each option is tested and controlled so your aluminium PCBs meet both thermal and electrical specs.
Quality, Certifications & Reliability
Our aluminium PCB production is backed by rigorous quality assurance standards:
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ISO 9001 certification — every batch is tracked, documented, and controlled.
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UL certified boards available if required for your application.
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RoHS / REACH compliance — lead-free materials and transparent component sourcing.
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Testing standards: IPC-A-600 compliance, full electrical testing, visual and AOI inspection.
We ensure that even with thermal and mechanical demands, each aluminium board is built to spec and maintained across runs.
Use Cases & Applications
Aluminium PCBs shine in scenarios where heat is a critical factor:
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LED lighting: For both signage and general illumination fixtures.
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Power conversion / supplies: Switch-mode power supplies, motor controllers, DC-DC converters.
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Automotive electronics: Modules in EVs, battery management systems, thermal management boards.
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Industrial sensors & actuators: Where dense electronics must be mounted to metal enclosures.
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Telecommunications / RF modules: Heat load from high frequencies demands thermal control.
Their efficiency and reliability across temperature cycles make aluminium PCBs a top choice in high-stress environments.
Aluminium PCB Manufacturing Process
Design & Data Preparation
You upload standard Gerber files. Our engineers review them for dielectric thickness, via placement, copper balancing, and thermal paths.
Core preparation & bonding
A thin insulating layer is bonded to the aluminium core, then copper layers are applied.
Drilling, plating & etching
Standard PCB procedures (drilling, through-hole plating, etching) are applied. Care is taken to preserve the dielectric and metal substrate integrity.
Solder mask, silkscreen & finish
Application of your selected solder mask and legend, followed by surface finish (ENIG, HASL, etc.).
Inspection & testing
We perform 100% electrical test / E-test, visual inspection, AOI, and adherence to standards such as IPC-A-600. Any board failing inspection is rejected or reworked.
Packaging & shipping
Boards are packaged with thermal isolation (foam, anti-static bags) and shipped via your preferred method. We manage all customs clearance and duty paperwork on your behalf.
Order Aluminium PCBs with Confidence — Get Your Quote Now
If your design demands high thermal performance, don’t settle for standard PCBs.
Upload your aluminium PCB design now to get a fast, no-obligation quote — or contact our technical engineers for guidance.
Frequently Asked Questions about Aluminium PCBs
Q1: When should I choose aluminium PCBs instead of FR4?
Aluminium PCBs are the best choice for applications that generate significant heat, such as LED lighting, power converters, and automotive modules. They provide superior thermal management compared to FR4, extending component lifespan and improving reliability.
Q2: Are aluminium PCBs more expensive than standard FR4 boards?
The unit cost of aluminium PCBs is slightly higher than FR4, but overall system costs can be lower. This is because aluminium reduces or eliminates the need for external heat sinks, fans, or larger housings, saving money in production and assembly.
Q3: Can aluminium PCBs be manufactured with the same features as FR4 PCBs?
Yes. Aluminium PCBs can support solder mask, silkscreen, vias, and even complex multilayer builds. While they are typically used in single- or double-layer designs, advanced stack-ups with thermal vias are also possible.
Q4: What industries commonly use aluminium PCBs?
They are widely used in LED lighting systems, automotive electronics, RF amplifiers, telecom infrastructure, power supply modules, and industrial control systems — anywhere heat dissipation is a priority.
Q5: Do aluminium PCBs have a longer lifespan?
Yes. Aluminium PCBs handle thermal cycling better than FR4 boards, meaning they resist cracking, delamination, and warping under repeated heating and cooling cycles. This makes them ideal for applications with continuous or heavy-duty operation.
Tate Circuit Industries Ltd
Unit 1 Europa Way,
Britannia Enterprise Park,
Lichfield, Staffs, WS14 9TZ, UK