Why Choose Consons?
- One-Stop PCBA Manufacturing Service from PCB to Functional Testing
- RoHS & REACH Compliant Lead-Free, Halogen-Free Materials
- ISO 9001 / IATF 16949 / ISO 13485 / UL Certified
- Complete MES Traceability for Every Production Batch
- 10+ Automated Lines with 10,000+ pcs Daily Capacity
One-Stop Power PCB Supplier in China
Consons is a professional provider of high-power PCB manufacturing and EMS assembly solutions. We provide one-stop power PCB services, covering PCB manufacturing, component sourcing, SMT assembly, and finished product assembly.
Our power PCB supports 2oz to 10oz heavy copper technology; it can handle continuous currents of hundreds of amps and maintain stable operation in high-power and high-heat dissipation applications. Also, we provide different thermal management solutions: aluminum PCBs, copper PCBs, and embedded copper blocks, to solve your heat dissipation challenges.
In addition, our factory is certified with IATF 16949 and UL certifications. Every power PCB will undergo 100% flying probe testing and impedance verification before shipment, to ensure reliable quality upon delivery.
Types of Our Power PCBs
These PCBs typically use 2oz–10oz copper layers, have natural thermal dissipation areas, and can handle kilowatt-level high currents on a single board.
These PCBs typically have a thermal conductivity of 1.0–5.0 W/m·K; this leads to an outstanding heat dissipation performance.
These PCBs use FR-4 and Rogers/Taconic hybrid laminate structures, which optimize high-frequency performance and reduce signal losses.
Copper blocks are embedded beneath IGBT/MOSFET areas to transfer heat directly to the heatsink backplate, so these PCBs also have outstanding thermal performance.
The PCB combines slots, chamfering, thick dielectric layers, and high-CTI materials; it can withstand continuous voltages above 2000V without creepage issues.
This type of PCB uses stacked vias and blind/buried via structures, which can achieve power module miniaturization. They are suitable for GaN fast chargers, PoE switches, etc.
Features of Consons’ Power PCBs
Supports long-term operation from -40℃ to 150℃. In addition, our automotive power domain Power PCB can pass 1,000 thermal cycling tests between -40℃ and 125℃.
Uses large pads and reinforced annular ring designs. It meets the automotive-grade ISO 16750-3 requirements for random vibration and mechanical shock.
Controls single-ended impedance at 50Ω and differential impedance at 100Ω, with a tolerance of ±10% or ±5%. We also provide TDR impedance test curves.
We use Tg 170℃/ 180℃ FR-4 materials as the PCB substrate, and this will prevent delamination even under extreme continuous thermal stress.
The inner layer copper thickness ranges from 2oz to 10oz, while the finished outer layer copper thickness can reach over 6oz. It also achieves kilowatt-level power transmission.
The aluminum PCB has a thermal conductivity of 1.0–3.0 W/m·K, while the copper PCB can reach 2.0–8.0 W/m·K.
We strictly follow IEC 60664-1 requirements and control the electrical clearance, the creepage distance. In multilayer PCBs, slots can be added to enhance the insulation.
All substrate materials in our product line comply with the UL94 V-0 flame retardant rating. We also offer high-CTI PCB materials with a CTI value of ≥600V.
Protect Your Intellectual Property and Data Security
Before starting the project, we will sign a Non-Disclosure Agreement (NDA) with you. At the same time, we have a comprehensive customer data protection system in place. All data transfers are encrypted using SSL, and our internal servers are managed through role-based access control.
In addition, the confidential materials, such as pilot production scrap boards and production films, will all be registered and either shredded, destroyed, or returned to you. All the disposal records can be audited.
Full-Process Quality Inspection
We strictly implement quality control measures, including 100% IQC incoming inspection, 100% AOI inspection, 100% X-ray drilling target alignment inspection, and full-point electrical continuity testing.
For every batch of substrate materials used for Power PCB production, we verify the material grade and production lot during incoming inspection, and conduct sampling checks on key parameters such as dielectric constant.
At each stage of production, we perform different inspections and tests. Before shipment, we conduct a final OQC inspection based on AQL 0.65/1.0 sampling standards to ensure PCB quality.
Specification
| Parameter | Our Capability |
| Layer Count | 1 – 30 Layers |
| Base Material | High-Tg FR-4, Aluminum Core, Copper Core, Rogers Hybrid |
| Glass Transition Temperature (Tg) | Std 150°C, High 170°C, Ultra 180°C |
| Flammability Rating | UL94 V-0 |
| Finished Copper Thickness | Outer 1-6oz, Inner 2-10oz |
| Min. Trace/Space | 0.25mm/0.25mm |
| Average Hole Wall Copper | ≥25μm avg, ≥20μm min |
| Impedance Control Tolerance | Standard ±10%, Advanced ±5% |
| Min. Solder Mask Bridge | 0.10mm (≥4mil) |
| Warp & Twist | ≤ 0.5% (Standard IPC-6012 Class 2) |
| Dielectric Withstanding Voltage | Up to 2,000+V DC |
| Surface Finish Options | LF HASL, ENIG, Imm Ag, Imm Sn, ENEPIG, OSP |
| ENIG Ni/Au Thickness | Ni 3-5μm, Au 0.025-0.05μm |
| Thermal Conductivity (Metal Core) | Al 1.0-3.0, Cu 2.0-8.0 W/m·K |
| Certifications | ISO 9001, IATF 16949, ISO 13485, UL, RoHS, REACH |
Applications of Power PCBs
The power PCBs can be applied in automotive systems like onboard chargers (OBC), DC-DC converters, electric power steering (EPS), motor controllers, and LED lighting modules. For different modules, we provide PCBs with corresponding manufacturing processes.
In the medical equipment field, different types of power PCBs are commonly used in applications such as high-voltage generators for CT rotating systems, medical laser pump power supplies, and MRI gradient amplifiers.
We support assembling power PCBs for high-power inverter main circuits, industrial UPS charging/inverter modules, and other power electronics applications. By using 10oz ultra-heavy copper PCB technology as a busbar replacement, the PCB can directly carry hundreds of amps of motor phase current.
In communication infrastructure power systems, the power PCBs can be applied in 5G AAU power modules, server power supply (PSU) synchronous rectification, and -48V busbar distribution boards.
We offer high-reliability PCBs with integrated blind/buried via technology, heavy copper hybrid stack-up processes, and support efficient, miniaturized power delivery solutions for communication equipment.
Our power PCB solutions can be widely used in products such as GaN fast chargers, professional amplifier power supplies, and LED display driver power supplies. With via-in-pad technology, aluminum substrates, and precision heavy copper traces, we will help you achieve high power density and compact thermal management designs.
For applications like centralized power supply for security surveillance systems, drone power modules, and aerospace-grade power systems, we also provide corresponding solutions. We offer high-Tg materials, heavy copper conductors, and conformal coating processes, which ensure stable operation even under high vibration and high humidity environments.
There is no minimum order quantity (MOQ) during the prototyping stage, and the orders can start from 1–5 pieces. For small-batch production (PVT), the MOQ starts from 50–100 pieces. For mass production, the standard batch quantity starts from 1,000 pieces.
Our lead time starts after the engineering review approval and receipt of the deposit. Prototype PCBs typically take 5–10 days, small-batch PCB production takes 12–20 days, and mass production takes around 20–30 days.
The lead time may vary slightly depending on PCB complexity. We will provide the estimated delivery time after completing the evaluation.
We provide transparent, itemized quotations, including the following costs:
- Engineering fee (NRE)
- Bare PCB cost
- Component cost (for one-stop service)
- PCBA assembly fee
- Functional testing (FCT) fee
- Packaging fee
In addition, the shipping costs are generally not included in the quotation.
We provide:
- At least 12 months warranty service
- Response to after-sales inquiries within 24 hours
- Free remake or refund for defective products without conditions
- Complete production records retained for each batch
We support EXW, FOB, CIF/CFR trade terms.
Yes. We have fully automated selective coating lines and provide UV inspection and coating thickness measurement reports. You can specify the coating areas and coating thickness (adjustable from 25 to 75 µm).
Yes. We support impedance testing according to IPC-2141A, or your specified target impedance values, and provide detailed test reports. The measurement capability covers signals with rise times ≤100ps and has an accuracy of ±5%.
For power PCBs operating above 1000V or carrying high currents (≥10A), we provide advanced manufacturing processes including heavy copper etching (3–6oz copper thickness for inner and outer layers), high-temperature-resistant substrates, reinforced insulation layers, electrical clearance design, efficient thermal management, and high-voltage testing.
To provide you with the most accurate quotation and DFM review, please provide the following files:
- PCB design files
- Drill files
- PCB stack-up drawings
- BOM list
- Pick-and-place coordinate files
- Other special requirement specifications
If you only have schematics or prototype photos, you can contact our engineers first. We will help you complete the necessary documentation.
Yes. We can handle standard export customs procedures and provide complete export documents, including commercial invoices, packing lists, customs declarations, and export licenses (if required). For destination customs clearance, we do not offer you direct agency services, but we will supply all necessary documents.
Get Your Customized Power PCB Solution
Send us your Gerber files, BOM, and design requirements, and we will give you a quotation and technical recommendations.