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2oz Copper PCB Thickness and its Design Guidelines

Introduction

Printed circuit boards (PCBs) form the core of electronic products,

providing the mechanical support and electrical connectivity for

components. An important characteristic of PCBs is the weight or

thickness of the copper foil used – typically specified in ounces per square

foot (oz/ft2). While 1oz copper has been the traditional standard, 2oz

copper PCBs are being increasingly adopted in modern high performance

designs.

In this article, we will look at what 2oz copper PCB thickness means, why

2oz copper is preferred today, how it compares to 1oz, the key benefits

2oz copper provides, and the design guidelines to follow to best utilize the

advantages of this thicker copper PCB technology.

What is 2oz Copper PCB?

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The copper thickness or weight on a PCB is specified in ounces per square

foot (oz/ft2). This refers to the weight of copper foil in a square foot area,

not counting the weight of the insulating fiberglass substrate. Some

typical copper weights are:

 1/2oz – 0.5 oz/ft2 (17 μm)

 1oz – 1 oz/ft2 (35 μm)

 2oz – 2 oz/ft2 (70 μm)

 3oz – 3 oz/ft2 (105 μm)

So a 2oz copper PCB uses 2 ounce of copper foil per square foot on each

metal layer. This equals a copper thickness of about 70 μm (micrometers)

or 2.8 mils. The key benefits of 2oz over standard 1oz copper are:

 Lower electrical resistance and losses

 Ability to handle higher currents

 Improved heat dissipation

 Better electromagnetic and EMI shielding

 Higher reliability under temperature swings and current stresses

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Why Use 2oz Copper instead of 1oz?

While 1oz copper PCBs have been widely used in the past, 2oz copper

offers a number of advantages driving its increasing adoption:

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Higher Currents – Electronic devices are handling ever

increasing power levels. The thicker 2oz copper can carry over twice the

current of 1oz copper without overheating. This reduces the number of

layers needed.

Lower Loss – The 2x lower resistivity cuts resistive losses in half compared

to 1oz copper. This improves power efficiency and signal quality.

Finer Lines/Spaces – The thicker copper allows narrower trace widths and

spacing which helps increase PCB component density.

EMI Shielding – With increasing circuit speeds, electromagnetic

interference (EMI) is a growing concern. The thicker 2oz copper provides

superior shielding against EMI.

Thermal Dissipation – The excellent thermal conductivity of copper helps

spread heat better and improves thermal management with 2oz copper

boards.

Reliability – Under temperature swings and current stresses, 2oz copper

suffers less electrical migration issues and dendrite growth over long-term

use.

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High Speed – Lower resistance and inductance of 2oz copper traces

enhances high speed signal quality in today’s high

frequency digital circuits.

Component Miniaturization – Finer 2oz copper features allow matching

PCBs to smaller, closely spaced component packages.

Cost – Although 2oz copper is costlier than 1oz materially, this is offset by

lower layer count, improved yield and better reliability.

Key Benefits of 2oz Copper

Let’s examine some of the technical advantages of 2oz copper PCBs in

more detail:

1. Lower Electrical Resistance

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Copper is the standard PCB conductor due to its high electrical

conductivity. Its volume resistivity is 1.72 x 10^-6 ohm-cm. For

a given cross-section area, increasing copper thickness decreases

resistance proportionally.

The table below shows resistivity comparisons for common PCB

trace widths:

Trace Size 1oz Resistance 2oz Resistance % Resista

10 mils 19.8 mΩ/inch 9.9 mΩ/inch ~50%
5 mils 39.6 mΩ/inch 19.8 mΩ/inch ~50%
3 mils 66 mΩ/inch 33 mΩ/inch ~50%
2 mils 99 mΩ/inch 49.5 mΩ/inch ~50%
1 mil 198 mΩ/inch 99 mΩ/inch ~50%

(Table data assumes standard 1.4mil trace height and bulk copper

resistivity)

We can see the 2oz copper thickness cuts conductor resistivity in half

versus 1oz material. This lowers losses like I2R heating, improves power

efficiency, reduces voltage drops, and minimizes cross talk.

2. Increased Current Carrying Capacity

The maximum current a PCB trace can safely carry without overheating is

proportional to the copper cross-sectional area. By doubling thickness

from 1oz to 2oz, the cross-section and current capacity approximately

doubles.

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For example, a common 10 mil wide trace can handle:

 1.2A max on 1oz copper

 2.4A max on 2oz copper

This helps reduce the layer count for heavily loaded boards by carrying

more current per layer with 2oz copper.

3. Finer Trace Resolution

The thicker 2oz copper can be etched to finer trace widths and spacing

compared to 1oz material. Width and space down to 2-3 mils is achievable

with 2oz boards.

This denser trace resolution enables complex, high component density

PCBs with fine geometry to route traces between closely placed small

components.

4. Lower Inductance Wiring

For high frequency AC signals, the magnetic flux penetrating the loop area

of a wire produces self-inductance which increases with current frequency.

This self-inductance can distort signals.

2oz copper traces have less inductance than thinner 1oz traces. Because

inductance reduces with increasing conductor thickness while keeping

loop area constant. This improves high frequency AC performance.

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5. Better Electromagnetic Shielding

With fast switching digital circuits, controlling stray electromagnetic

interference (EMI) is critical. A solid copper plane or enclosure provides

effective EMI shielding.

The thicker 2oz copper offers superior shielding compared to 1oz material

by reducing penetration of magnetic fields. It also has higher reflection

attenuation for radiated fields.

6. Improved Thermal Management

The excellent thermal conductivity of copper (385 W/m-K) allows it to

rapidly conduct heat away from hot spots and spreading it over the PCB

area. Thereby lowering peak temperatures.

With 2oz copper, the higher copper mass reduces thermal resistance in

the planes. This keeps the board and components cooler during

operation.

7. Lower Impedance Ground/Power Planes

Continuous ground and power planes are commonly used

in multilayer PCBs. At high frequencies, these planes have non-zero

impedance which causes noise if large currents flow.

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2oz copper planes reduce this impedance due to larger thickness.

Resulting in cleaner power distribution and lower ground noise.

8. Better Power Handling and Reliability

The combination of lower operating temperature, reduced current density,

lower electromigration and thicker copper gives 2oz boards greater

long-term reliability under electrical and thermal stresses.

This enhances product life span and reduces field failures – critical factors

for applications like automotive, aerospace and medical electronics.

9. Improved Manufacturing Yield

The thicker 2oz copper is inherently more resistant to defects like nicks,

scratches and denting during PCB fabrication handling. This leads to

higher manufacturing yields and lower costs.

Also, improved etch control results in fewer open or partially open traces

reducing scrap and rework. The higher yield offsets the marginally higher

2oz material cost.

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Applications that Benefit from 2oz Copper

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Some types of PCB designs and applications that can take particular

advantage of the superior performance of 2oz copper are:

High Power Electronics – Power devices for HVAC, motor

drives, battery charging, power supplies etc. need heavy duty PCBs to

handle large currents without overheating.

Automotive Electronics – Under-hood circuits for engines, drivetrains and

auxiliary systems require high reliability PCBs with 2oz copper for the

thermal and vibration extremes.

LED Lighting – High brightness LED systems often operate at elevated

temperatures. 2oz boards keep the LEDs and drivers cooler for efficient

light output.

Power Amplifiers – Audio amplifiers and transmitters deal with

large RF signals. Low loss 2oz material ensures clean signal amplification.

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Computer Servers – High density computing clusters require dense 2oz

PCBs to interconnect many processors operating at high power levels.

Wireless Base Stations – Handling many simultaneous cellular signals

generates substantial heat. 2oz boards dissipate heat efficiently in the

crowded enclosure.

Defense/Avionics – Mission-critical aerospace systems demand maximum

reliability. 2oz copper provides this under demanding operating

conditions.

Medical – For implanted devices like pacemakers and monitors, 2oz PCBs

ensure robust operation under body thermal stresses and currents.

For such applications, 2oz copper is preferred over 1oz to leverage its

advantages while accepting the moderately higher cost.

Design Guidelines for 2oz Copper Boards

To fully optimize a design using 2oz copper thickness, engineers should

follow certain PCB layout guidelines:

Utilize Available Space – With 2oz copper allowing narrower traces and

spacing, component placement can be more dense. Spread components

out to utilize the extra space.

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Minimize Trace Lengths – The low resistivity of 2oz copper means less

need for fat traces. Use the space for routing shorter, more direct

connections.

Reduce Layer Count – Lower current density enables removing layers if

layout permits. But maintain adequate ground/power planes.

Use Smaller Vias – Taking advantage of the finer 2oz resolution, vias can

be shrunk maintaining routing density.

Increase Component Density – Smaller package components packed

closer together are now easier to interconnect with thinner 2oz traces.

Watch AC Impedance – For sensitive high frequency signals, keep narrow

2oz traces short and avoid thin/long traces.

Remove Thermal Reliefs – If suitable for components/leads, thermal reliefs

can be eliminated to reduce thermal resistance.

Increase Copper Fills – Use more copper pours for thermal and EMI

shielding. Maintain isolation from traces.

Reduce Plane Splits – Minimize splits in ground and power planes. Use

more vias for connections through splits.

Watch Spacing at Edges – Higher etch resolution can result in insufficiently

spaced traces along board edges.

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Refine Grids/DRC Rules – Tighten clearance grids and design rule checks to

match 2oz capabilities.

Account via-in-pad – Ensure designers consider via-in-pad rules for

densely placed vias.

With careful 2oz PCB layout practises, board sizes can be shrunk,

performance maximized and overall assembly costs potentially reduced.

Comparison Summary – 1oz vs 2oz Copper

Here is a summary comparison of key differences between standard 1oz

and 2oz copper PCBs:

Parameter 1oz Copper 2oz Copp

Copper Thickness 1 oz/ft2 (35 μm) 2 oz/ft2 (70 μm)
Trace Resistance Higher Lower by ~50%
Current Capacity Lower Nearly 2x higher
Inductance Higher Lower
Thermal Conduction Moderate Improved heat spreadin
EMI Shielding Moderate Better attenuation
Fine Line Resolution 3-4 mil lines/spaces 2-3 mil lines/spaces
Layer Count Typically higher Can potentially be low
Cost Lower Marginally higher
Reliability Moderate Enhanced under stresse

So for high current, fine pitch and demanding applications, 2oz copper is

preferable over 1oz to leverage its advantages.

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Frequently Asked Questions

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Q1. Is 2oz copper suitable for multi-layer PCBs?

Yes, 2oz copper material can be used on all layers of multilayer boards

equally well. The higher thickness still allows tight registration and

lamination.

Q2. Does solder mask adhesion differ between 1oz and 2oz copper?

There is negligible difference in solder mask adhesion between the two

copper thicknesses. The chemical bond to copper remains similar.

Q3. Can 2oz copper withstand soldering heat exposure?

Yes, the soldering temperatures typically used for PCB assembly are well

below the melting point of copper. So 2oz copper remains stable against

soldering heat.

Q4. How are vias drilled on 2oz copper boards?

Vias are typically made using laser drilling, which can easily drill through

the 2oz copper layer. Mechanical drilling is slower but possible too.

Q5. Is 2oz readily available from PCB manufacturers?

Nowadays most PCB fabricators offer 2oz copper as a standard option at

reasonable costs due to its widespread adoption. Quantity minimums may

be higher.

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Conclusion

With the increasing performance demands of modern electronics, 2oz

copper PCBs are becoming the preferred choice over traditional 1oz

material in many applications due to their many electrical, thermal,

reliability and fabrication advantages.

To fully leverage the lower losses, higher currents, improved resolution

and shielding possible with 2oz copper, designers must follow disciplined

layout practices specialized for the capabilities of thicker copper boards.

By combining robust 2oz PCB technology with optimized design

techniques, engineers can build electronics products with maximized

efficiency, density and reliability to meet the needs of the future.

Related Posts:

1. All You Should Know about HDI PCB Design Guidelines

2. PCB Design Guidelines For EMI EMC

3. GPS PCB Design Guidelines and its Importance in Todays Age

4. What are the Design Guidelines for Micro Circuit Boards?

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