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What we do – PCB manufacture






Printed circuit boards are at the very heart of today’s technological industry. They are used in every aspect of our lives, in telephones, amplifiers, computers, the automotive industry, medical equipment and almost every electronic appliance. With rapid advances in technology, electronic components must run faster and more efficiently, creating pressure to keep pace with customers’ demands in a changing market. This is why PCB fabricators and Original Equipment Manufacturers (OEM) share the same concerns. Manufacturers want reliable, low cost printed circuit boards that meet even the most critical design requirements, including high frequencies, fast speeds and heat dispersion. As a supplier as well as a PCB assembler, BPC Electronics LLP is committed to providing quick production, on-time deliveries and competitive prices on consistently reliable circuit boards that users can depend on time and time again. Our PCB fabrication facilities are UL+ISO-9001 certified, capable of producing single-sided PCBs, double-sided and multilayer circuit boards (up to 12 layer) using FR4, CEM-3 and polyimide materials. We can accept a wide variety of PCB design file formats including Gerber, Protel and AutoCAD. We take pride in being able to provide competitive pricing together with the highest quality PCBs by producing them expediently at our offshore facilities. In our current economy cost and long term reliability are very important and with BPC Electronics LLP you have the ideal manufacturing partner. We aim to provide the best service to our customers, be it for a fast delivery 12 oz copper PCB , or a scheduled order for printed wire circuits. See below for more information on the types of printed circuit board we use.

FR4 (fibreglass) based printed circuit boards

Over eighty percent of the PCBs we supply are made from FR-4 material. FR-4 is the grade designation for glass reinforced epoxy laminate printed circuit boards. It is made of woven fibreglass with an epoxy resin binder that is flame resistant. FR-4 is the primary insulating backbone upon which the vast majority of rigid PCBs are produced. A thin layer of copper foil is laminated to one, or both sides of an FR-4 glass epoxy panel. These are commonly referred to as copper-clad laminates.In the UK, copper foil thickness is specified in units of ounces per square foot (oz/ft2). One ounce copper foil has a weight of one oz/ft2. This works out to a thickness of 34,1 µm (1,34 mils).

FR-4 glass epoxy is a popular and versatile high pressure plastic laminate grade with good strength to weight ratios. With near zero water absorption, FR-4 is most commonly used as an electrical insulator possessing considerable mechanical strength. The material is known to retain its high mechanical values and electrical insulating qualities in both dry and humid conditions. These attributes, along with good fabrication characteristics, lend utility to this grade of printed circuit board for a wide variety of electrical and mechanical applications, from jukeboxes to stair lifts.


LED PCBs

BPC Electronics LLP has been working closely with manufacturers of LED based products for nearly a decade. Architectural and industrial lighting designers have been migrating to LED technology, abandoning traditional lamps or bulbs because of the lower production and installation costs. However, high intensity LEDs create problems of heat, especially when closely grouped clusters are involved. Excessive heat generated on a standard printed circuit board results in inefficient thermal transfer and allows isolated “hotspots” beneath devices. The use of a heat sink aids thermal dissipation but is limited by the inefficient FR4. BPC manufacture aluminium backed circuit boards by bonding a metal plate of various thicknesses to a range of high thermally dissipating dielectrics, allowing the heat to be spread across the entire area of the PCB and through to the metal base efficiently and without locking heat into isolated areas. This technology can be applied to the commonly used single sided PCB, but also to PTH and multilayer designs. FR4 dielectric can be utilised where possible and improved with the addition of thermal via holes plated directly to a copper base or by using in combination with thermal dielectrics in multilayer applications.
Advantages of Aluminium Metal backed printed circuit boards:

  • Dissipates heat without the use of extra heat sinks
  • Reduces / eliminates the need for fan forced air cooling
  • Cooling properties allow devices to be driven harder or substituted with cheaper components
  • Reduces the effect of thermal stress on all components
  • Enables PCB size to be reduced
  • Improves product mean time between failures
  • Excellent EMI-EMC shielding characteristics

BPC Electronics LLP has considerable experience in the manufacture and supply of metal backed PCBs using metals such as aluminium as well as copper and offers very competitive pricing. Metal backed PCBs can be manufactured with aluminium or copper metal in various thicknesses and with a choice of solder mask and legend colours. Final profiling of metal backed circuits can be routed, supplied as individual circuits or supplied in a v-cut panel.


Heavy copper weight & copper core based printed circuit boards

Another example of BPC Electronics LLP's more technical range of products is 12 ounce copper printed circuit boards. These are made of layers of thick copper foil, also known as “thermo–layers” and are available in thicknesses of up to 400 micron (12 oz.). They can be used in multilayer PCB constructions as inner layers or even outer layers (with inner signal layers and isolated vias). Such metal substrate technology can allow designers to remove or reduce the size of heat sinks or cooling fans, thus saving space. BPC Electronics LLP have considerable experience in this area together with the manufacturing expertise to meet even the most demanding requirements. Amongst our customers we have world renowned subcontractors to the automotive manufacturing sector as well as research establishments in the top 10 members of the respected Russell Group

Not so long ago, no one could manufacture a printed circuit board that could handle currents in excess of 400 amps. Quite a few PCB manufacturers now offer this high priced option, but with a big increase in power applications there was a need for printed circuit boards using heavier copper content. BPC Electronics LLP has been delivering heavy copper circuit boards up to 6 ounces since the late 1990s. Our expertise is in producing reasonable priced, heavy copper PCBs for applications as diverse as power converters and welding equipment The main advantage of the heavier copper boards is their ability to withstand repeated exposure to over current, higher temperatures and repeated thermal cycling that would destroy a “normal” PCB in seconds. The heavy copper circuit board can survive a lot of punishment, which makes it well suited to applications in rugged environments, such as the aerospace and defence industries. The obvious disadvantage of the higher price of the heavy copper boards compared to conventional equivalents is offset by its durability and the possibility of attaching large relays and capacitors directly onto the circuit.


FLEXI RIGID PCB

Some printed circuit boards are designed to be very or slightly flexible, using polyimide film technology. This type of board, sometimes called a flexi circuit or rigid-flexi circuit, is tricky to manufacture but has many applications. Flexi boards are useful where space is at a premium, for example, inside digital cameras or hearing aids, where they can be folded up to fit into the limited available space. A recent order from a local manufacturer involved a flexi PCB used inside an electronic torque wrench!

The flexible part of the circuit board can often be used as a cable or moving connection to another board or device. You can see these in everyday devices such as inkjet printers. Flexi rigid PCBs are often used in power electronics applications which require low-thermal resistivity substrates, with thick copper tracks to carry high currents. The main technologies are ceramic-based substrates (direct bonded copper) and metal-based substrates (insulated metal substrates). Flexi boards are very versatile and will create savings in space and weight for product designers and come in all sorts of shapes and sizes as you will see from the pictures on this page.

If you would like more information, advice or technical information please email us at: sales@bpc-electronics.com or call us on +44 116 234 7025.

Please take a moment to view our case studies by clicking either the link at the top of the page or here

To get a quotation please email us at the address above or click here for an online quote

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