24 Layer Heavy Copper Aluminum Metal PCB Board 6.5mm Thick 6000V For EV Charging Power Module

24 Layer Heavy Copper Aluminum Metal PCB Board for EV Charging Power Modules

Built for traction and charger platforms that push continuous current past 400A, this 24 layer heavy copper aluminum metal PCB board pairs a 20 OZ outer copper layer with a 6.5mm finished thickness. The aluminium metal core spreads heat away from the switching devices, so IGBT and SiC modules hold their junction temperature inside a narrow band even during repeated fast-charge cycles.

Design advantages engineers ask for

• 24 layer stack-up with 15 OZ inner copper for high current distribution without busbar jumpers
• 6000V dielectric withstand voltage, hipot tested on 100% of panels
• Aluminium metal substrate with 2.0-3.0 W/m.K thermal path for heat spreading under power stages
• 0.05mm minimum laser-drilled microvia for dense BGA and gate driver routing
• Impedance controlled within +/- 8% for CAN, LIN and isolated sensing traces
• Finished thickness up to 6.5mm, warp held under 0.5% for press-fit assembly

Technical specification

Where it is used

On-board charger stages, DC-DC converters, battery management power rails, motor inverter gate drivers and charging pile heat sinks. The heavy copper core carries the full charge current with fewer parallel paths, which simplifies the busbar layout and lowers assembly cost.

How we build and inspect it

Panels are laminated in a controlled press cycle, then drilled on UV laser lines for the 0.05mm microvias. Each lot goes through AOI, flying probe electrical test, hipot at 6000V and a 100 cycle thermal shock check before packing. A first article report with cross-section photos ships with the pilot batch.

Customisation options

Layer count, copper weight, board outline, thermal pad windows, press-fit holes, impedance targets and marking are all made to drawing. Send Gerber plus stack-up notes and our engineering team returns a DFM review within 24 hours.

Packing and lead time

Vacuum packed with desiccant, separated by anti-static foam, shipped in export grade cartons with edge protection. Samples in 7-10 days, volume production 15-25 days depending on layer count.

Tell us your current, voltage and thickness target and we will quote the heavy copper stack-up that fits it.