How to Choose the Right PCB Thickness? Best Options for Different Applications
- Sunsoar engineer Mia
- May 12
- 3 min read
In the world of electronics manufacturing, choosing the right PCB thickness is a critical yet often underestimated decision. The thickness of a printed circuit board (PCB) directly influences its mechanical strength, electrical performance, and suitability for specific environments or product types. Whether you're developing a wearable device, an industrial control unit, or a high-frequency RF board, getting the thickness right can make the difference between failure and success.
So how do you choose the right PCB thickness? Let’s break it down from both a technical and application-specific perspective.
Standard PCB Thickness: The Industry Baseline
The most common PCB thickness used in the industry is 1.6 mm (0.063 inches). This standard was originally adopted due to the mechanical compatibility with traditional connectors and enclosures. Today, it remains a safe and cost-effective option for many general-purpose applications including consumer electronics, lighting modules, and simple IoT devices.
However, one size doesn’t fit all—different products have very different performance requirements.
Factors That Influence PCB Thickness Selection
1. Current Carrying Capacity
Thicker copper layers (e.g., 2 oz or 3 oz) require a corresponding increase in board thickness to avoid overheating. For high-power applications like motor drivers or power converters, PCB thickness often goes up to 2.0 mm or more to accommodate thermal management needs.
2. Flexural Strength
Thin PCBs (such as 0.4 mm or 0.6 mm) are flexible and suitable for compact products like smart cards or flexible displays. But these thin boards are more prone to warping or cracking under mechanical stress, especially in multilayer configurations.
3. Impedance Control
In high-speed digital circuits, consistent dielectric thickness is essential for signal integrity. Controlled impedance PCBs, especially for applications like USB, HDMI, or RF antennas, often use precise thicknesses like 0.8 mm or 1.0 mm to maintain strict signal trace geometries.
4. Component Height and Assembly
For embedded or compact designs, engineers may need to reduce PCB thickness to fit tight enclosures. Conversely, for devices requiring connectors, heavy components, or sockets, a thicker board (e.g., 2.4 mm or more) helps maintain durability.
5. Thermal Dissipation
Heat dissipation is crucial for LED modules, power amplifiers, and industrial controllers. Thicker boards can spread heat better, particularly when combined with metal core PCBs (MCPCBs) or additional thermal vias.
Best PCB Thickness by Application
✔️ Consumer Electronics (Wearables, Smart Home)
Recommended: 0.6 mm to 1.2 mm
Benefit: Compact form factor, low cost, good for signal routing
✔️ Automotive & Industrial Controls
Recommended: 1.6 mm to 2.4 mm
Benefit: High mechanical strength, vibration resistance
✔️ RF & High-Frequency Circuits
Recommended: 0.8 mm to 1.0 mm (with high-frequency laminates like Rogers)
Benefit: Better impedance control, low signal loss
✔️ Power Electronics (Inverters, Chargers)
Recommended: 2.0 mm to 3.2 mm with heavy copper
Benefit: Higher current capacity, better heat handling
✔️ LED Lighting Modules
Recommended: 1.0 mm to 1.6 mm on aluminum base
Benefit: Excellent thermal conductivity
Custom Thickness Solutions at Sunsoar
At Sunsoar PCB, we understand that every product has unique design challenges. That’s why we offer custom PCB thickness options ranging from 0.2 mm to 6.0 mm, including:
Multi-layer PCB solutions (up to 48 layers)
Heavy copper PCBs (up to 10 oz)
Flex and rigid-flex options
MCPCB for high-power LEDs
Our engineering team can help you analyze trace width, impedance needs, and thermal performance to recommend the most suitable thickness for your project. Unlike some fast-turnaround PCB factories that only offer limited stack-up options, we specialize in tailored solutions without minimum order quantity (MOQ) requirements.
Why Choose Sunsoar Over Competitors?
Competitors like JLCPCB and PCBWay excel in low-cost prototyping, but they often limit you to a few standard thicknesses unless you pay extra for customization. RayPCB and ALLPCB provide decent global service but may not offer the same technical consulting and rapid prototyping integration as we do.
At Sunsoar, we combine cost efficiency, flexibility, and technical depth. From quick sample builds to full turnkey PCBA services, our team works closely with hardware startups, industrial OEMs, and EMS partners worldwide. With full IPC and ISO certification and over 15 years of experience, we’ve delivered reliable PCB solutions to over 80 countries.
📧 Contact us at sales03@sunsoartech.com📞 Phone: +86 13632793113🌐 Learn more: www.pcbsun.com📺 Subscribe to our channel: YouTube - Sunsoar PCB
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