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Aluminium PCB thickness and copper: choosing 0.8 to 1.6 mm and 35 or 70 µm
Every aluminium MCPCB order needs four build details: board thickness, copper weight, solder mask colour and finish. This guide covers what we make, what we have built for common LED products, and how to choose.
Sara Circuits team · 1 November 2026
What we make, in one table.
All our aluminium boards are single-sided: one copper layer on a thin dielectric bonded to an aluminium base. MCPCB full form
| Build detail | Options at Sara Circuits |
|---|---|
| Board thickness | 0.8 mm to 1.6 mm |
| Copper | 35 µm (1 oz) as standard; 70 µm (2 oz) where the design needs it |
| Solder mask | White (standard for LED boards); green or black on request |
| Surface finish | HASL or OSP |
| Profiling | Punched on blanking dies for volume, CNC routed, or V-cut into strips Punching vs routing |
| Minimum order | 40 m² per design. Below 40 m², regular customers only, with a ₹2,500 development charge 40 m² in pieces |
Board thickness: what we have built.
Thickness is your design decision, set by your housing and assembly line. These are real aluminium builds from our floor:
| Board | Thickness | Copper | Finish | Profile |
|---|---|---|---|---|
| 112 mm round DOB | 1.6 mm | 35 µm | HASL | Ready die, white mask |
| Emergency bulb board, 62 mm | 1.6 mm | 35 µm | HASL | Ready die |
| LED batten strip | 1.0 mm | 35 µm | OSP | V-cut strips that snap apart after assembly |
Two practical points:
- On punched boards, keep holes at least one board thickness from the outline so edges do not crack.
- If your round board matches one of our 21 ready dies, the die sets the outline, so there is no tooling charge and no tool lead time. Ready dies
Not sure which thickness to use? Send the Gerber and your current board or sample; we confirm the build after reviewing your files.
Copper: 35 µm or 70 µm.
35 µm (1 oz) is the standard and suits most LED and driver boards. 70 µm (2 oz) is for high current: high-current boards usually need 70 µm or wider tracks. 70 µm costs more, so use it only where the current needs it.
To check a track, use our trace width calculator. It gives an estimate for straight tracks in still air, for 35 µm and 70 µm copper at a 10, 20 or 30 °C rise. PCB design tools
Heat: what the copper layout has to do.
On an aluminium MCPCB, heat from the LEDs passes through the thin dielectric into the metal base and spreads out, so the LEDs run cooler and keep their brightness longer than on paper or glass-epoxy boards. The layout decides how well that works:
- Use the LED maker's recommended footprint and keep thermal pads large.
- Keep copper continuous under and around each LED to spread heat into the base.
- Undersized pads cause tilted LEDs and dark spots after reflow.
Aluminium is the choice where heat decides LED life: high-power LEDs, DOBs and closed housings. CEM3 can work for low-power battens and decorative lights at lower cost. Aluminium PCB vs FR4
Solder mask and finish.
White solder mask is standard for LED boards because it reflects light back out of the fitting. Green and black are available on request.
For the finish, we offer HASL or OSP. The DOB and emergency bulb boards above ran with HASL; the batten strip ran with OSP. Tell us which your line uses.
What to send for an aluminium PCB quote.
- Gerber files, or the outline if you want to check it against our ready dies first.
- Board thickness (0.8 to 1.6 mm) and copper (35 or 70 µm).
- Mask colour and finish (HASL or OSP).
- Quantity per design for the first order, and your expected monthly quantity.
- Any creepage your product standard needs, if mains voltage is on the board (DOB). DOB PCB design guide
Every design gets a CAM check and you approve a PDF before any material is cut. Fast, accurate quotes
Questions? Answers.
What thickness of aluminium PCB do you make?
Single-sided aluminium MCPCB from 0.8 mm to 1.6 mm thick, with 35 µm (1 oz) or 70 µm (2 oz) copper.
Which copper weight should I use on an LED board?
35 µm suits most LED and driver boards. Use 70 µm or wider tracks for high current. Trace width calculator
Which solder mask colour is best for aluminium LED boards?
White, because it reflects light back out of the fitting. Green and black are available on request.
Do you offer HASL and OSP on aluminium PCBs?
Yes. Both are available; tell us which your assembly line uses.
Do you have ready dies for round aluminium boards?
Yes. Round LED bulb boards from 38 to 66 mm, emergency bulb boards, and DOB boards at 82, 112 and 132 mm. A matching outline means no tooling charge. Ready dies
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Send us your design.
Attach the Gerber, tell us the material and quantity, and we will come back with a price.