Why Choose Consons?
- Provide Free and Comprehensive DFM Reviews With Detailed Reports
- Certified With ISO 9001, IATF 16949, ISO 13485, ISO 14001, and UL Certifications
- Every Control PCB Has a Unique Serial Number for 100% Traceability
- Control PCB Prototypes Start From 1 Piece, and Engineering Ones From 5 Pieces
- Provide One-Stop Services Covering Control PCB Manufacturing to Functional Testing
One-Stop Controller PCB Supplier in China
Consons is a professional EMS provider that specializes in high-performance controller PCB manufacturing and assembly. We provide a one-stop solution, covering bare PCB manufacturing, component sourcing, SMT assembly, and final product assembly for your projects.
We are capable of manufacturing high-precision control boards from 4 to 30 layers. You can also choose advanced processes including heavy copper for high current carrying capacity, precision impedance control, and blind/buried vias.
For every PCB, we ensure quality through strict impedance control within ±5% or ±10%, along with 100% flying probe testing and AOI inspection. At the same time, our entire manufacturing process strictly follows IATF 16949 and ISO 13485 quality systems, ensuring every delivered PCB is fully traceable.
Types of Our Controller PCBs
It supports up to 30 layers and enables lossless transmission of 10Gbps-level signals, which is suitable for data center switches, 5G base station controllers, and high-end PLC systems.
These PCBs support copper thicknesses up to 6oz or even 10oz, use pattern plating and differential etching compensation technologies, and have excellent creepage safety.
It uses laser microvia and any-layer interconnect technology, which can achieve extremely high component density.
It uses low-Dk/Df materials such as Rogers and Megtron 6, combined with FR-4 hybrid lamination, to achieve extremely low dielectric loss and strict phase consistency.
This type of PCB integrates rigid circuit areas and flexible connection areas into a single PCB, achieving lightweight design and optimized signal paths.
It uses high-Tg (≥170℃) halogen-free materials and passes 3,000 rigorous thermal cycling tests (-40℃ to +125℃), which can ensure driving safety.
Features of Consons’ Controller PCB
We offer FR-4 material options with Tg ≥150℃ (mid-Tg), Tg ≥170℃ (high-Tg), and Tg ≥180℃ (ultra-high-Tg), which can meet the industrial applications’ thermal stability requirements.
We support manufacturing copper thickness from 1oz (35μm) to 6oz (210μm) that meet the requirements of both high-density signal routing and high-current carrying.
All of our PCB materials meet the UL94 V-0 flame retardant rating that may reduce the risk of arcing and short circuits. For high-voltage ones, we can also provide materials with CTI ≥600V.
We use high-Tg materials with low Z-axis expansion characteristics, which can operate normally under -40℃ to +105℃ and meet the requirements of outdoor environments.
For automotive and rail transit controllers, we reinforce PCB edges with rounded corners and enhanced mounting hole designs, to prevent solder joint fatigue cracking.
Our PCBs support ENIG finishing and conformal coating processes, achieving 96-hour salt spray resistance and can handle moisture corrosion and insulation failure.
We will sign an NDA with you and use encrypted storage for your engineering data, including Gerber files, BOM, assembly drawings, and other documents, to protect your data security.
Each Control PCB has a unique serial number and uses MES to record all the data in real time. When failure occurs, the issue can be quickly traced.
Complete Quality Inspection Process
Consons strictly controls the quality of every PCB. Before production starts, we perform a full IQC inspection on all incoming materials to identify and remove defective parts. After SMT assembly, we carry out 100% AOI optical inspection and X-ray inspection, to make sure the accuracy and reliability of solder joints.
After PCB assembly, we conduct strict quality testing, including 100% flying probe/fixture electrical testing, controlled impedance TDR testing, destructive physical analysis (DPA), and environmental and thermal stress testing. The corresponding test reports will also be shipped to you.
Customized Special Process Capabilities
Consons provides different customized PCB solutions, including blind and buried vias, any-layer interconnection (ALIVH), hybrid stack-up, special-shaped PCB designs, internal cavity routing, thermal-electrical separated metal core PCBs, and deep etching compensation for heavy copper circuits.
We also support HDI structures, resin plugging and copper capping for BGA pads, and hybrid material lamination processes, which may meet your different PCB requirements.
Specification
| Item | Options |
| Number of Layers | 2 to 30 layers |
| Board Thickness | 0.4mm to 3.2mm |
| Base Material | FR-4, High Tg, Rogers |
| Glass Transition (Tg) | 150°C, 170°C, 180°C |
| Copper Weight | 1oz to 6oz |
| Min. Line/Space | 3/3 mil (75/75μm) |
| Impedance Tolerance | ±10% standard, ±5% available |
| Min. Hole Size | 0.2mm mech., 0.1mm laser |
| Hole Copper Plating | 25μm avg., 20μm min. |
| Surface Finish | ENIG, HASL, Immersion Ag, OSP |
| Via Process | Blind, Buried, VIPPO |
| Solder Mask Color | Green, Blue, Black, White |
| Warp & Twist | ≤ 0.5% |
Applications of Controller PCBs
Our controller PCBs comply with IATF 16949 requirements and are suitable for automotive applications, such as Engine Control Units (ECU/ECM), Battery Management Systems (BMS), On-Board Chargers (OBC), and DC-DC converters. It can handle high and low temperature shocks, ensuring stable operation for power control and in-vehicle power conversion systems.
Consons’ controller PCB supports multilayer HDI, precise impedance control, and low-loss materials; they are suitable for medical applications such as patient monitor main control boards, infusion/injection pump control units, and medical imaging equipment backplanes.
In industrial applications, the controller PCB can be used for PLC CPU boards, inverter and servo drive control boards, industrial PC (IPC) mainboards, and backplanes. It can withstand vibration, high-current surge impacts, and bring out high-speed computing, high-voltage insulation, and stable 24/7 continuous operation.
The control PCB is also suitable for 5G base station timing control boards, router and switch main control modules, and optical transmission equipment monitoring boards. It can transmit high-speed massive data and synchronized control signals with stability.
Our control PCB can deal with high current, high-voltage DC, severe temperature variations, and strong vibration environments. It can be used as photovoltaic inverter MPPT control boards, energy storage converter (PCS) control units, wind turbine pitch control and main control boards.
For normal motor drive control boards, 1oz (35μm) copper thickness is enough. As for the power circuits that drive MOSFETs/IGBTs and carry high-current PWM signals, we recommend that you use 2oz–4oz (70–140μm) heavy copper.
For high-power servo drives and industrial inverters, you can choose 6oz (210μm) copper thickness, or even higher.
Yes. We support precision impedance control with tolerances of ±10%, ±8%, and ±5%. Every batch of the PCB will be shipped with an impedance test report.
We will conduct the following tests while meeting IATF 16949, and give you the test reports:
- Thermal stress test: 288°C solder float test for 10 seconds, 3 cycles, to verify delamination resistance.
- Temperature cycling/shock test: To verify the reliability of solder joints and plated through holes (PTH) under temperature conditions from -40°C to +125°C.
- CAF test: To verify insulation reliability under high humidity and high voltage conditions.
- Microsection analysis: To verify copper thickness in vias, interlayer bonding quality, and plating quality.
If you only need a PCB quotation, please provide the Gerber files (RS-274X format), drill files, and the manufacturing specifications.
If you need component sourcing and PCBA assembly service, apart from the above files, please give us the BOM, pick-and-place (coordinate) files, and the assembly drawings.
The standard mass production lead time is:
- Double-sided PCBs: 2–3 working days
- 4-layer PCBs: 4–5 working days
- 6–8-layer PCBs: 6–8 working days
- 10-layer and above PCBs: To be confirmed, usually 10–15 working days
We also provide flexible expedited services, with multilayer PCB production available in as fast as 48–72 hours.
We have long-term cooperation with international express carriers: DHL, FedEx, and UPS. Also, you can choose different trade terms, including FOB, CIF, and DDP. Under the DDP term, we can prepay import duties on your behalf.
If any quality issue occurs, our after-sales team will respond to you within 4 hours and retrieve the MES production traceability data. During the warranty period, if the issue can be confirmed to be caused by manufacturing defects, we will provide free replacement boards or a full refund at no additional cost.
Get Your Customized Controller PCB Solution
Simply send us your Gerber files, BOM, other technical requirements, and our engineers will analyze them and give you the best solution!