Facts Behind Flux60 HE Series - Aluminium PCB

In the manufacturing of the Ws Flux 60 HE PCB, we do face certain process challenges. We need to laser-drill tens of thousands of micro-holes, each only 0.03mm in diameter, into a large aluminum plate, then fill these holes with resin to create an insulation layer, and finally laminate the PEP and copper foil together. (PS: this is the alu PCB material for 4 Flux60 HE PCBs)

In comparison, the aluminum substrates used in automotive headlights typically require no drilling or insulation treatment and are single-sided, making their production relatively simpler. Our design, however, is double-sided—a rarity in aluminum substrate manufacturing and considerably more complex.

The Ws Flux 60 HE PCB features dense wiring, a high number of vias, and intricate circuitry, which increases manufacturing difficulty and carries certain risks. If the insulation layer is not properly applied, the entire board may be rendered defective. During the initial trial production of 2,000 aluminum substrate units, over 1,600 failed due to insulation issues, resulting in a defect rate of approximately 80%. Despite this, we remain committed to advancing this process, all to deliver a product with superior performance and greater reliability for our users.

If you are interested, please check out: 

https://shop.wuquestudio.com/products/ws-flux60-he-the-1st-alumium-hall-effect-pcb