Custom Automotive PCBs: Built for Speed. Built for Safety.

December 4, 2025

Latest company news about Custom Automotive PCBs: Built for Speed. Built for Safety.
1. Definition & Core Function

Automotive PCBs are specialized circuit boards engineered for vehicles. They serve as the central nervous system, interconnecting and controlling electronic components like engine control units (ECUs), sensors, infotainment systems, and ADAS (Advanced Driver Assistance Systems). Unlike consumer PCBs, they must withstand extreme operational environment.

2. Key Characteristics Automotive PCBs are defined by stringent requirements:
  • Environmental Resilience: Operate at -40°C to 150°C, resist humidity, salt spray, and chemical exposure.
  • Vibration/Shock Resistance: Survive 50G+ mechanical shocks and continuous vibration (e.g., ISO 16750 standard).
  • High Reliability: ≤10 FIT (Failures in Time) rate – critical for safety systems like airbag controllers.
  • Multi-layer Design: 6–20+ layers with HDI (High-Density Interconnect) technology for complex routing.
  • Materials: High-Tg FR-4, polyimide, or ceramic substrates for thermal stability; heavy copper (up to 6 oz) for power handling.
3. Advantages Over Standard PCBs
  1. Safety Compliance: Mandatory for ASIL (Automotive Safety Integrity Level) systems.
  2. Longevity: Outlasts vehicle warranties (e.g., 100,000+ operating hours).
  3. Signal Integrity: EMI/RFI shielding prevents interference in critical systems.
4. Flow Automotive PCB production involves rigorous steps:
  1. Design & Simulation:
    • CAD tools (e.g., Altium) for layout; EMI/thermal simulations.
    • DFM (Design for Manufacturing) checks to avoid field failures.
  2. Material Prep:
    • Selection of high-Tg laminates (e.g., Isola TerraGreen® for low loss).
    • Copper foil treatment for adhesion.
  3. Multi-layer Lamination:
    • Sequential build-up of layers with prepreg bonding.
    • Vacuum lamination to eliminate air pockets.
  4. Drilling & Plating:
    • Laser drilling for micro-vias (≤100μm).
    • Electroless copper + electrolytic plating for via filling.
  5. Etching & Patterning:
    • Photolithography for 35μm trace widths.
    • AOI (Automated Optical Inspection) for defect detection.
  6. Testing & Validation:
    • Electrical Tests: Flying probe/ICT for opens/shorts.
    • Environmental Tests: Thermal cycling (-55°C↔125°C, 1,000+ cycles), HAST (Highly Accelerated Stress Test).
    • Reliability Tests: Vibration/shock simulations.
5. Critical Applications
  • Powertrain: ECU, transmission control.
  • Safety: Airbag controllers, ABS.
  • Comfort: Climate control, seat modules.
  • Connectivity: 5G/V2X antennas, infotainment.
  • EV-Specific: BMS (Battery Management Systems), OBC (On-Board Chargers).