Copper Inlays | PCB | High-Current Circuit Boards

Copper inlay PCBs are a special circuit board solution in which massive copper inserts (inlays) are directly integrated into the board. This technology is primarily used to safely conduct high currents and effectively dissipate heat, which is crucial in power and high-current applications. Typical areas of use include power converters, automotive electronics, power modules, or industrial drives.

In short: copper inlay PCBs are the solution when standard conductor tracks are no longer sufficient for current or thermal management.

Cross-section of a 4-layer copper inlay PCBF

The manufacturing process of copper inlay PCBs is similar to that of standard multilayer boards. However, before lamination, the inlay areas (“pockets”) must be milled out in the inner layers. Copper pieces of the corresponding shape are then manually inserted into these pockets.

Pre-milled solid copper plate

Several prepregs with a higher resin content ensure during lamination that the copper inlays are precisely fixed and that the gaps to the inner layer are completely filled with resin.

Solid copper plate being inserted into the “pockets”

After lamination, the PCB is processed further using conventional methods. Plated-through holes into the copper inlays are, of course, possible.