Electronics Sourcing quizzed Daleba Electronics’ Tony Hawkins about the driving forces behind the increasing popularity of ceramic printed circuit boards.
Why are we seeing growth in the popularity of ceramic PCBs?
Growth is being driven by increasing demand for high-performance electronic systems. Industries are facing challenges such as miniaturisation, high-power requirements and the need for excellent thermal management. Ceramic PCBs address these challenges exceptionally well.
Unlike traditional materials like FR4, ceramics offer outstanding thermal conductivity, withstand extreme temperatures and provide low signal loss for high-frequency applications. These properties make them an ideal choice for demanding sectors.
What makes ceramics unique compared to other PCB materials?
Heat dissipation is a standout feature of ceramics. With no dielectric components can be placed directly on the ceramic substrate without the need for an isolation layer, which significantly improves heat flow. Thermal conductivity can range from 24 to 180 W/mK—far superior to other materials. Ceramics are also highly resistant to chemicals, UV and moisture (and don’t outgas), suiting them to environments where contamination or moisture could cause failures.
Where are ceramic PCBs being widely adopted?
Ceramics are finding applications in aerospace, defence, automotive, medical, industrial, power and wireless. For example, they’re used in guidance systems, automotive powertrains, optical devices, CT scanners and RF devices. Their ability to perform reliably in high-temperature, high-frequency environments makes them indispensable in these fields.
What role does thermal management play in their popularity?
Thermal management is crucial in modern electronics. As devices become more compact and powerful, they generate more heat which must be effectively managed to ensure reliability and longevity. Ceramic PCBs excel here because of their high thermal conductivity and ability to withstand operating temperatures above 300°C. This suits applications like power inverters and industrial automation equipment, where overheating could lead to costly failures.
What are the trends in materials and manufacturing methods?
Materials like Alumina Oxide (Al₂O₃) and Aluminium Nitride (AlN) are popular choices. Al₂O₃ is cost-effective and widely used, while AlN offers even better thermal conductivity for applications that demand the highest performance. Directly plated copper (DPC) also allows for two-layer through hole plated boards.
Tell us about Daleba’s work with CERN involving ceramic PCBs?
CERN approached Daleba for ceramic circuits for its Beam Instrumentation group. These instruments monitor particle beams, which exist in ultra-high vacuum conditions. In this environment, any outgassing or contamination could compromise the system. Ceramic PCBs were the perfect solution due to their hermetic properties and ability to perform in extreme conditions. Daleba supplied Al₂O₃ ceramic PCBs, which are now used in several ‘in-beam’ instruments at CERN.
How do ceramic PCBs contribute to advancements in wireless communication?
Ceramic PCBs are increasingly used in wireless devices like base stations and RF devices because of their low signal loss and excellent heat dissipation. These properties are essential in maintaining signal integrity and managing the heat generated by high-frequency operations. As advanced communication technologies expand, ceramics will play a pivotal role in supporting their infrastructure.
What are the challenges associated with ceramic PCBs?
One challenge is their higher production cost for short runs compared to traditional PCBs. However, this is offset by their performance benefits and longer lifespan in demanding applications. Another consideration is the complexity of designing and manufacturing ceramic PCBs, but advancements in technology are making this process more accessible. Daleba has invested in the expertise and resources to overcome these challenges and deliver reliable solutions to its customers.
What advice would you give engineers considering ceramic PCBs for the first time?
Start by assessing the application’s requirements for thermal performance, durability and frequency. If these factors are critical, ceramics might be the best choice. Work with a supplier like Daleba that has experience in ceramic technology and can provide guidance on material selection and design optimisation. With the right partner, transitioning to ceramics can unlock new levels of performance.
Finally, why should customers choose Daleba Electronics as their ceramic PCB supplier?
Daleba brings over 60 years’ PCB manufacturing expertise and a commitment to delivering high-quality solutions. The company has worked with world-leading organisations like CERN, demonstrating its ability to meet the most demanding requirements. The UK-based team combines technical knowledge with personalised service, ensuring customers receive the right solution for their needs. Whether customers are designing for aerospace, medical or industrial, Daleba is ready to help harness the power of ceramic PCBs.