We manufacture high-reliability medical heavy copper PCBs designed for high-power, high-current healthcare applications. We support up to 100 oz, and mixed-copper weight configurations.
• ISO 13485, ISO 9001 & IPC Class 2/3 certified manufacturing.
• Up to 100 oz Copper Weight for extreme power and thermal management.
• Heavy, Extreme & Mixed Copper weight options available.
A medical heavy copper PCB is a printed circuit board built with copper weights ranging from 3 oz to 100 oz, to handle high current, reduce electrical resistance, and dissipate heat efficiently. Compared with standard PCBs, heavy copper boards provide lower electrical resistance, improved heat dissipation, and greater mechanical strength. They are widely used in medical power supplies, imaging systems, surgical equipment, and other healthcare devices that require stable electrical performance, efficient thermal management, and long-term reliability.
Our manufacturing facilities strictly comply with ISO 13485 standards and IPC-A-610 Class 2/3 guidelines. Every heavy copper PCB undergoes rigorous quality protocols to meet strict healthcare regulations and ensure life-critical device safety.
Our engineering team conducts a complimentary Design for Manufacturability (DFM) review on every project. We analyze trace spacing, copper weight balance, and thermal relief to identify design risks early, preventing costly production delays and re-spins.
Etching heavy copper structures requires extremely precise process control. MedPCB utilizes differential etching techniques to maintain accurate trace geometry across heavy copper designs, including projects requiring copper weights.
Capable of processing extreme copper weights from 3 oz to up to 100 oz, MedPCB supports ultra-high power density designs without compromising structural integrity. This extreme copper capacity allows custom medical hardware to deliver high-amperage power reliably within minimal physical footprints.
Heavy copper PCBs demand substrates that withstand severe thermal expansion. We utilize high-Tg FR-4 and polyimide base materials engineered to improve thermal stability while minimizing warpage and delamination.
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Process |
Standard |
Advanced |
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Copper Thickness
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Minimum 1/2 OZ Maximum 4 OZ |
Minimum 1/3 OZ Maximum 100 OZ |
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Layer
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1–20 layers |
22–40 layers |
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Material |
Standard FR-4 materials, including KB, Shengyi, FR408, IS410, GETEK, 370HR, IT180A, and other common laminates.
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High-performance materials such as Rogers, PTFE laminates, Taconic, Arlon, Nelco, and hybrid FR-4/RF laminates. |
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Finished Board Thickness |
0.2–3.2 mm |
3.4–10 mm |
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Minimum Tracking/Spacing |
Internal Trace/Space: External Trace/Space: |
Internal Trace/Space: External Trace/Space: |
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Maximum Board Size
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Up to 500 × 600 mm |
Up to 1000 × 500 mm |
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Surface Finish |
Standard lead-free & HASL finishes |
Advanced finishes (Gold Finger, Hard Gold, ENIG+OSP) |
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Soldermask
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Green, Black, Blue, Red, White, Yellow, Purple Matte/Glossy |
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Via Process
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Tenting Vias, Plugged Vias and Unplugged Vias |
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Testing
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Fly Probe Testing, Electrical Testing (E-test) and AOI Testing |
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Production begins by selecting the appropriate PCB substrate and copper foil based on the board's electrical, thermal, and mechanical requirements. For improved trace accuracy, heavy copper PCBs typically use thinner base copper before building up the required copper thickness through plating.
Common substrate materials:
Challenge: Etching thick copper up to 10 oz requires extreme chemical control. A minor over-etching error can alter trace widths by up to 0.005 inches, compromising power capacity and overall circuit performance.
Our Solution: MedPCB utilizes advanced differential etching equipment and automated chemical metering. This achieves tight trace tolerances down to 0.010 inches with clean, straight sidewalls for optimal power distribution.
Challenge: Significant thermal expansion mismatches between heavy copper and dielectric substrates during high-temperature reflow can cause layer separation or board warping.
Our Solution: We use high-Tg FR-4 and polyimide substrates combined with multi-stage, pressure-controlled lamination processes to keep delamination risks below 0.1%, ensuring long-term thermal stability.
Challenge: Specialty substrates, extended etching cycles, and thick copper plating increase manufacturing costs by 20% to 50% compared to standard FR-4 circuit boards.
Our Solution: Our engineering team conducts a complimentary DFM optimization review to eliminate unnecessary board layers, optimize copper weight distribution, and reduce overall unit cost without sacrificing power integrity.
Challenge: Most standard PCB fabricators lack the heavy-duty plating lines, high-capacity chemical baths, and specialized equipment required to process copper weights above 6 oz.
Our Solution: MedPCB operates specialized heavy copper manufacturing lines capable of plating up to 100 oz copper. Our ISO 13485-certified facility guarantees consistent quality and fast turnaround times for medical-grade power PCBs.
To meet the demands of high-power, space-constrained electronics, standard heavy copper plating methods are sometimes paired with specialized manufacturing techniques. MedPCB supports both Embedded Copper Coin and Integrated Bus Bar for heavy copper PCBs.
To manage extreme thermal loads in localized areas without increasing the copper thickness across the entire board, MedPCB offers embedded copper coin technology. Solid copper coins are embedded directly into pre-cut cavities within the PCB substrate beneath high-power components. This creates a direct, high-conductivity metallic pathway to draw heat away from sensitive electronics rapidly, ensuring optimal thermal dissipation while maintaining a flat, even board profile.
MedPCB can also integrate solid copper bus bars directly onto or within the PCB structure. This hybrid design significantly boosts current-carrying capability while dramatically reducing circuit footprint, assembly costs, and overall system weight. Bus bar integration offers high electrical efficiency with minimal thermal resistance, making it ideal for heavy-duty medical machines.
Need a reliable medical heavy copper PCB manufacturing partner? Contact MedPCB today for a fast quotation and expert engineering DFM support.
High-reliability power delivery PCB for dual-energy X-ray bone densitometry systems, supporting consistent low-dose radiation control and stable long-term power management.
Heavy-duty circuit board for real-time continuous X-ray imaging equipment, featuring thick copper traces that handle sustained high currents while preventing thermal overheating.
High-power distribution PCB for high-speed CT gantry drives and generator units, engineered with heavy copper layers to deliver rapid current surges and superior heat dissipation.
High-voltage power controller board for diagnostic X-ray exposure systems, providing enhanced dielectric strength, robust trace reliability, and zero power dropouts during high-intensity exposure cycles.
High power PCB for precision RF surgical units, featuring high-voltage isolation, rapid thermal dissipation, and ultra-stable energy delivery for reliable cutting and coagulation.
Our Medical Heavy Copper PCB FAQ addresses essential questions regarding your manufacturing requirements. We cover our capabilities for complex medical electronics, supply chain management, assembly timelines, rigorous quality inspection protocols, and our capacity to scale from initial builds to production batches. For every medical device project, we guarantee precision-focused, medical-grade assembly standards.
1–4 layers
Up to 5 W/m·K
35 µm–240 µm (1 OZ–7 OZ)
4–40 layers
Standard: 500 × 600 mm (19" × 23") Advanced: 1100 × 500 mm (43" × 19")
High-Tg FR4, Rogers, Polyimide, Megtron, Taconic, Arlon
4–40 layers
Supports 1+N+1, 2+N+2, and Any-Layer HDI
Microvias, Fine Lines, and Sequential Lamination
1–4 layers
Min ½ OZ, Max 4 OZ standard; Min ⅓ OZ, Max 100 OZ advanced
Aluminum, FR4, copper, ceramic, polyimide, polyester, glass, and hybrid laminates
1 to 8 Layers
Static 3-6x (1L) | Dynamic 20-40x
Polyimide (PI), FR4, 3M Tape
01005 (0.4mm*0.2mm)
Support SMT & Thru-hole
Turnkey, Partial turnkey, Consigned
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