Can You Handle High-frequency (RF/microwave) PCBs? Materials?

Introduction

High-frequency PCBs, particularly those used in RF (Radio Frequency) and microwave applications, require specialized materials and manufacturing expertise. Unlike standard FR-4 PCBs, these boards must maintain signal integrity, minimize dielectric losses, and withstand extreme thermal conditions. A common question we encounter is:

"Can you handle high-frequency (RF/microwave) PCBs?"

The answer is a resounding Yes! We specialize in high-frequency PCB fabrication using advanced materials such as Rogers (RO4003C, RO4350B), PTFE (Teflon), and hybrid PCB board constructions. In this article, we’ll explore:

- Why material selection is critical for high-frequency PCBs

- Key properties of Rogers RO4003C and other high-performance laminates

- Our manufacturing capabilities with real-world examples

- Applications that benefit from these materials

Why Material Selection Matters for RF/Microwave PCBs

High-frequency signals are highly sensitive to dielectric properties, conductor losses, and thermal stability. The wrong material can lead to:

- Signal Attenuation–Excessive loss at high frequencies

- Impedance Mismatch–Leading to reflections and degraded performance

- Thermal Instability–Causing warping or delamination under heat

Key Material Properties to Consider:

1. Dielectric Constant (Dk)–Must be stable across frequencies (e.g., Rogers RO4003 Chas a Dk of 3.38±0.05 at 10 GHz).

2. Dissipation Factor (Df)–Lower loss means better signal integrity (RO4003C: 0.0027 at 10 GHz).

3. Thermal Conductivity–Critical for heat dissipation in power amplifiers.

4. Coefficient of Thermal Expansion (CTE)–Must match copper to prevent via cracking.

Rogers RO4003C: The Ideal High-Frequency PCB Material

One of our most trusted materials for RF/microwave PCBs is Rogers 4003C, a ceramic-filled hydrocarbon laminate that combines PTFE-like performance with FR-4-like manufacturability.

Key Features of RO4003C:

✔Low Signal Loss–Df of 0.0027 at 10 GHz ensures minimal attenuation.

✔Stable Dk–3.38±0.05 across frequencies, crucial for impedance control.

✔Excellent Thermal Stability–Tg >280°C prevents warping in high-heat environments.

✔CTE Matched to Copper–Reduces via failure risk in thermal cycling.

✔Cost-Effective Processing–No special treatments needed (unlike PTFE).

Example PCB Using RO4003C + S1000-2M

We recently manufactured a 6-layer RF PCB with the following specifications:

- Base Material: RO4003C + S1000-2M

- Layer Count: 6 layers

- Board Dimensions: 356mm x 373mm (±0.15mm)

- Min Trace/Space: 4/4 mils

- Min Hole Size: 0.35mm

- Finished Thickness: 2.0mm

- Surface Finish: HASL

- 100% Electrical Testing

PCB Stackup Details:

This stackup ensures low insertion loss, controlled impedance, and mechanical stability—critical for high-frequency designs.

Other High-Frequency PCB Materials We Work With

While RO4003C PCB is excellent for many applications, we also support:

1.Rogers RO4350B PCB –Higher thermal conductivity (0.69 W/m/K) for power amplifiers.

2. PTFE (Teflon)–Ultra-low loss (Df ~0.001) for mmWave and aerospace applications.

3. Hybrid Constructions–Combining FR-4 with high-frequency materials for cost optimization.

Applications of 6-layer hybrid circuit board PCBs

Our 6-layer hybrid circuit board PCBs are used in demanding industries, including:

- 5G & mmWave Communications–Antennas, beamforming arrays

- Radar & Defense Systems–Missile guidance, avionics

- Satellite & Aerospace–Low-earth orbit (LEO) antennas

- Medical Imaging–MRI and RF ablation devices

Why Choose Us for Your RF/Microwave PCBs?

✅Material Expertise–Deep knowledge of Rogers, PTFE, and hybrid materials.

✅Precision Manufacturing–Tight tolerances (4/4 mil trace/space,±0.15mm dimensions).

✅Rigorous Testing–100% electrical testing before shipment.

✅Fast Turnaround–Prototype to production support.

Conclusion

When it comes to high-frequency (RF/microwave) PCBs, material selection and manufacturing precision are non-negotiable. Whether you need Rogers RO4003C, PTFE, or hybrid constructions, we have the expertise to deliver low-loss, high-reliability PCBs for your most demanding applications.

Need a quote for your high-frequency PCB project? Contact us today!