For engineers battling heat in power electronics, Al PCB un-plated holes isolated with resin solves a fundamental conflict: achieving electrical isolation while maximizing thermal transfer in aluminum-based boards. At MeidearPCB, we’ve perfected this resin-hole insulation technology to enable robust DIP component mounting on high-conductivity aluminum substrates—without compromising reliability or performance.

Why Insulation Holes Matter in Aluminum IMS?

Aluminum’s conductivity makes it ideal for heat dissipation in LEDs, power converters, and automotive systems. However, its conductive nature prevents direct mounting of through-hole (DIP) components—pins contacting the metal base would short-circuit. Traditional workarounds like secondary brackets add cost, bulk, and thermal barriers.

Our solution? Aluminum PCB with Insulation holes uses precision-drilled un-plated cavities filled with thermally stable epoxy resin. This creates isolated “islands” for solder anchoring, enabling secure DIP assembly while preserving aluminum’s 2W thermal conductivity Al PCB properties.
 

Engineered for Electrical Safety & Thermal Dominance

Aluminium (IMS) boards excel where heat kills conventional FR4 PCBs. But standard designs fail with pin-through components. Our resin-hole technology bridges this gap.

Structure & Materials: Precision Layering

• Base Layer (1.0–3.0mm Aluminum): 5052 or 6061 alloys offer optimal thermal spread (180–230 W/m·K) and CTE matching78.

• Dielectric Insulation (75–150μm): Ceramic-filled polymer with >3kV breakdown voltage and 1.2–2.5 W/m·K conductivity3.

• Circuit Layer (1–10oz Copper): Heavy copper supports high-current traces.

• Insulated Holes: Laser-drilled cavities filled with epoxy resin, creating solderable, non-conductive zones.
   

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The Resin-Isolation Process: How It Works

1. Drilling: Un-plated holes are CNC-drilled into the aluminum core.

2. Resin Filling: High-purity epoxy is vacuum-injected, ensuring void-free sealing.

3. Curing: Thermal treatment solidifies the resin, achieving >40MPa bonding strength6.

4. Patterning: Copper is etched for circuitry, with resin holes acting as component anchors.
   The result? Pins solder only to copper pads—not the aluminum base.
   

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Thermal & Electrical Performance

• Thermal Conductivity: 2.0 W/m·K dielectric + aluminum base dissipates 8× faster than FR478.

• Voltage Isolation: Resin holes withstand 15kV/mm, eliminating leakage risks10.

• CTE Matching: Aluminum’s 4.5 ppm/°C expansion rate reduces solder-joint stress near power ICs7.

Advantages Over Conventional Metal PCBs

1. Dual-Purpose Aluminum Core: Acts as both heatsink and structural support. Eliminates separate heatsinks—cutting weight/cost by 30%810.

2. Reliable DIP Mounting: Resin holes secure transformers, connectors, or capacitors without metal-contact shorts. Vibration resistance exceeds MIL-STD-202G10.

3. Simplified Assembly: No adhesives or hardware needed. Compatible with reflow/wave soldering.

4. Extended Lifespan: Operating temperatures reach 150°C—ideal for LED automotive lighting or industrial motor drives28.

5. Customization: Supports Milk white soldermask for LED reflectivity, 1–10 layers, and 0.4–3.2mm PCB thickness.

Real-World Applications: Where Insulated-Hole Aluminum PCBs Excel

• High-Power LED Systems: Resin holes anchor driver ICs in street/industrial lights. Aluminum draws heat from 200W+ COB arrays, reducing lumen decay2.

• EV Chargers & Converters: Mount relays or transformers directly on 2W thermal conductivity Al PCB, shrinking assembly size 40% while handling 15A+ loads.

• Industrial Power Drives: Isolate IGBT modules in motor controllers. The aluminum base cools heatsinks passively—no fans needed.

• Telecom Power Supplies: Support high-wattage through-hole inductors in 5G base stations.

About MeidearPCB: Your Thermal Management Partner

MeidearPCB (www.me-pcb.com) specializes in Metal PCB solutions, with core expertise in Aluminium (IMS), copper, and ceramic substrates. Our capabilities include:

• Advanced Thermal Boards: Offering 2W thermal conductivity Al PCB designs with resin holes, 2L layers, or flexible dies.

• End-to-End Service: From design support (DFM analysis) to prototyping (<5 days) and high-mix volume production.

• Quality Compliance: Certifications include IATF 16949, UL 94V-0, and IPC-6012 Class 2.

• Niche Mastery: 60% of projects involve thermal-critical applications like automotive LEDs or aerospace sensors—where our resin-hole technology ensures 99.98% field reliability10.
   

Upgrade to Smarter Thermal Management!

Why risk thermal runaway or assembly failures? Our Al PCB with un-plated holes isolated with resin delivers electrical safety, heat dissipation, and component stability in one solution.

→ Request a Quote & DFM Review Today!
Submit your design files to mkt@me-pcb.com for a resin-hole Al PCB prototype in 72 hours.

→ Get Professional One Stop PCB Solution From Us!