LED PCB Fabrication Service , Heavy Copper PCB Design And Fabrication
LED PCB | MCPCB & Heavy Copper High-Thermal Solutions | Industrial & Automotive Lighting | DuxPCB
At DuxPCB, we specialize in high-performance LED printed circuit boards engineered for thermal efficiency, reliability, and superior light output. Whether you are developing commercial lighting, automotive headlights, street lamps, or high-density LED displays, our LED PCBs deliver the thermal management and electrical performance your application demands.
LEDs generate significant heat during operation. Without effective thermal dissipation, performance degrades rapidly, leading to reduced lifespan and color shift. Thermal design is at the core of our LED PCB solutions.
We offer three primary types of LED PCBs to match your specific power, thermal, and cost requirements.
Aluminum LED PCBs
- Excellent thermal conductivity, typically 1 to 3 W/m·K
- Lightweight and cost-effective
- Ideal for general lighting, automotive LED modules, and consumer electronics
Copper-Based LED PCBs
- Superior thermal conductivity exceeding 400 W/m·K
- Best suited for ultra-high-power applications such as industrial lighting and UV LEDs
- Delivers unmatched heat dissipation performance
FR-4 with Thermal Enhancements
- Cost-optimized for low-to-mid power LED applications
- Incorporates localized thermal vias or hybrid metal-core structures for improved heat transfer
| Feature | Specification |
|---|---|
| Base Materials | Aluminum 1.0–3.2 mm, Copper 0.8–2.0 mm, FR-4 with thermal enhancements |
| Thermal Conductivity | Aluminum: 1.0–3.0 W/m·K Copper: up to 400 W/m·K |
| Layer Count | 1 to 8 layers standard, up to 10 layers for complex designs |
| Minimum Trace/Space | 4 mil / 4 mil on standard aluminum 3 mil / 3 mil available for advanced designs |
| Board Thickness | Aluminum: 0.8–3.2 mm FR-4 variants: 0.4–2.4 mm |
| Solder Mask | White, Black, Green, Red, Blue |
| Surface Finish | HASL lead-free, OSP, Immersion Silver, ENIG |
| Thermal Features | Direct thermal pads under LEDs, via-in-pad, plated through-hole thermal vias |
| Maximum Panel Size | 1200 * 600 mm |
| Quality Certifications | ISO 9001, ISO 14001, IATF 16949 |
| Testing | Flying probe test, AOI inspection, optional thermal imaging |
| Lead Time | 3 to 7 days standard, 2-day expedited service available |
Use white solder mask on aluminum LED PCBs to maximize light reflectivity and improve lumen output.
- General Lighting – LED bulbs, tubes, downlights
- Automotive – Headlights, daytime running lights, interior lighting
- Outdoor and Industrial – Streetlights, tunnel lights, high-bay fixtures
- Consumer Electronics – Backlighting, indicator panels, smart displays
- Specialty Lighting – UV sterilization, horticultural grow lights, stage lighting
As a vertically integrated manufacturer, DuxPCB provides comprehensive services including:
- LED PCB prototyping and volume production
- Component sourcing and full turnkey PCBA assembly
- Thermal simulation and design support including Gerber review and stack-up optimization
- CNC metal housing and heat sink integration
We help you reduce development time, lower total cost, and accelerate time to market while ensuring high reliability under demanding thermal conditions.
Upload your Gerber files or complete our online quote form to receive an instant price. Our engineering team will review your design and provide free DFM feedback within four business hours.
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Have questions about our products or want to discuss a custom order? Our team is ready to help you.