Insulated Metal Substrate (IMS) PCBs
Superior Thermal Management for High-Power Applications
High-power applications demand thermal solutions that go beyond the limits of conventional FR-4 designs. At HT Global Circuits, we specialize in the design and fabrication of insulated metal substrate (IMS) PCBs engineered for exceptional heat management, mechanical durability, and electrical performance.
As a trusted metal core PCB manufacturer, we deliver custom metal core PCBs that enable engineers to push power density, longevity, and reliability across thermal-intensive applications. Whether you need a quick-turn metal core PCB prototype or a fully optimized high-volume production run, HTGC combines technical insight with production agility to meet your performance, cost, and timeline goals.
Metal Core PCB (MCPCB) Capabilities
This table explores our full range of capabilities in manufacturing single-sided, double-sided, and multilayer metal core PCBs.
| Specification | Capability |
|---|---|
|
Number of layers |
1 – 4 layers |
|
Materials |
Core (Aluminum, copper, brass) Dialetric (FR-4, polyimide, CEM3) |
|
Copper foil weights (finished)
|
0.5 – 6 ounce
|
|
Minimum trace and spacing
|
2.4 / 2.4 mils
|
|
PCB thickness
|
0.32″ |
|
Surface finishes
|
HASL, Lead-free HASL, OSP, ENIG |
|
Minimum drill
|
4.0 mils |
|
Maximum dimensions
|
32″ x 52″
|
|
Special processes |
Counter sink, Sidewall silver platting, Bonding, Castelated holes, Carbon ink, Peelable solder mask |
|
Metal core thickness
|
0.5mm to 3.0mm
|
|
Copper weights |
1-10 oz |
|
Operating temperature range |
-50°C to +150°C |
|
Breakdown voltage |
up to 6kV |
Certifications
Our production facilities produce in accordance with the IPC-A-600, IPC 6011 and IPC 6012 standards and have been awarded all the key certificates:
Beneficial Features of Rigid PCBs
Insulated metal substrate PCBs provide significant engineering benefits for high-power, thermally constrained applications. Here’s how they outperform conventional PCB technologies.
- Exceptional Thermal Conductivity: IMS PCBs leverage aluminum or copper metal cores with much higher thermal conductivity than standard FR-4.
- Aluminum base: 1–12 W/m·K
- Copper base: Up to 400 W/m·K
- Standard FR-4: ~0.3 W/m·K
This enables rapid heat transfer from components to the metal base, improving system stability and longevity.
Low Thermal Resistance
By creating a direct thermal pathway from surface-mounted components through the dielectric to the metal core, the metal core circuit board minimizes junction temperatures. This reduces the need for bulky heat sinks and increases power density in compact designs.
Superior CTE Matching
With a Coefficient of Thermal Expansion (CTE) closely aligned to most semiconductor packages, metal core PCB design reduces thermal stress during operation. This protects solder joints and components from fatigue, especially in high cycle or temperature-varying environments.
Dielectric Material Flexibility
IMS PCBs offer flexibility in dielectric material selection, allowing you to choose between standard insulation and high-thermal-conductivity dielectric materials (up to 3.0 W/m·K). This customization optimizes both electrical isolation and thermal efficiency, ensuring your design meets specific performance and power dissipation requirements.
Applications of Custom Metal Core PCB
HTGC’s insulated metal substrate PCBs are trusted across industries where thermal reliability and power density are imperative. Our metal core PCB fabrication services support a broad range of high-performance applications, including.
- LED Lighting Systems: Our aluminum PCBs for LED lighting provide exceptional heat dissipation, allowing high-lumen output without sacrificing LED lifespan. They are widely used in automotive headlights and DRLs, architectural floodlighting and commercial and residential LED panels.
- Power Electronics: Our range of single-sided and double-sided metal core PCBs are ideal for power converters, motor drives, on-board chargers, and switch-mode power supplies, where thermal control directly impacts efficiency and safety.
- Automotive Electronics: Our single-sided and double-sided metal core PCBs are designed to withstand extreme temperatures and mechanical stress in EV battery packs, engine and transmission control units and lighting and driver assistance systems.
- Industrial Automation & Robotics: In high-duty-cycle environments, metal core PCB (MCPCB) units help ensure reliable power delivery with minimal thermal fatigue. A few of the application areas of our single-sided metal core PCB units include robotic controllers, welding and CNC equipment and motor controllers.
- Renewable Energy Systems: Being a trusted IMS PCB manufacturer, we have been dedicatedly serving the renewable energy sector. Our metal core circuit boards are used in solar and wind systems, wind turbine blade pitch controls, and MPPT power optimization modules, among others.
Why Choose HT Global for IMS PCBs?
Design engineers and sourcing teams rely on HTGC’s technical depth and full-stack manufacturing support.
Here’s what sets us apart.
- Material Expertise: We guide you in selecting the most suitable metal, such as aluminum 5052/6061 or copper C110, and dielectric materials based on your application’s thermal load, electrical requirements, and cost considerations.
- Thermal Simulation at Design Stage: Our engineering team can run thermal simulation models during layout planning to validate heat dissipation, optimize component placement, and prevent performance bottlenecks, ensuring the most efficient metal core PCB design before fabrication.
- High-Power Component Integration: We design for advanced power packages like TO-220, TO-247.
- Integrated Thermal Solutions: HTGC provides complete thermal management systems, including custom-fitted heatsinks, mechanically secured baseplates, and high-reliability metal-core stack-ups for seamless integration into your end-product.
- Thermal Design Considerations: HTGC brings decades of metal core PCB (MCPCB) design experience to help you engineer thermally efficient, mechanically sound layouts. We proactively offer the following services:
Via placement and copper balancing.
Solder mask and pad treatments for high-temperature durability.
Flatness and mechanical integrity for multilayer or large panels.
- Scalable Supply Support: At HTGC, we provide end-to-end manufacturing solutions, from design validation to full-scale production, with a focus on speed, consistency, and quality. Our capabilities include:
- Quick-Turn Prototyping: We offer quick turn metal core PCB services to help engineering teams iterate fast and reduce time to market. Our prototype cycles are optimized for rapid thermal validation and electrical testing.
- Domestic & Offshore Production: With both local and offshore fabrication capabilities, we handle everything from small pilot runs to high-volume orders, without compromising on precision or material traceability.
- Quality Certifications: All boards are produced to IPC Class 2 or Class 3 standards, and we offer UL certification upon request to meet global compliance requirements for safety and durability.
Get your PCBs Built – Fast
HT Global Circuits delivers quick-turn, high-quality PCBs with transparent pricing and reliable delivery. Order now to keep your projects on track.
Frequently Asked Questions
IMS PCBs provide superior heat dissipation by integrating a thermally conductive metal base. This offers better performance and reliability in high-power applications compared to standard FR-4 PCBs.
Yes. HTGC manufactures single-sided, double-sided, and multilayer metal core PCBs with advanced via structures and insulation strategies, depending on your thermal and electrical requirements.
Yes. Our IMS PCBs are compatible with SMT, wave soldering, and reflow processes. We also offer custom surface finishes and solder mask treatments for high-temperature reliability.
We offer aluminum cores (5052 and 6061 grades) and copper cores (C1100) depending on the required thermal conductivity, mechanical strength, and cost-performance balance.
Our quick turn metal core PCB services deliver fully fabricated business days, depending on the complexity and material availability.
- Optimal thermal management requires careful planning of:
- Copper weight(thicker copper improves heat distribution)
- Dielectric layer thickness(thinner = better conduction but lower voltage isolation)
- Component placement(high-power devices should align with metal core pathways)
Our engineering team provides free DFM reviews to optimize your layout before fabrication.