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What are Castellated Holes in PCB?

Introduction

Printed circuit boards (PCBs) contain plated through holes and vias to

allow mounting of electronic components and electrically connecting

traces across layers. Castellated holes are a special type of plated through

hole that provide a unique way to extend PCB connections to external

devices or boards.

This article will provide a comprehensive overview of castellated holes,

discussing their characteristics, design considerations, fabrication process,

applications and benefits compared to other interconnect methods.

What are Castellated Holes?

Castellated holes are plated half-holes located on the edge of a PCB. They

extend from the outer layer to just one inner layer, unlike regular through

holes that span the entire board. The name comes from their

resemblance to turrets or castellations along the edge of a castle wall.

As seen above, half of each plated hole protrudes outside the PCB edge,

while the other half extends inwards to connect to an internal layer. This

provides a means to electrically connect the external region and internal

board layers via the metal plating in the castellated hole walls.

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The exposed cylindrical pads can be used for direct vertical

interconnection between boards stacked on top of each other.

Castellations perform a similar function to edge connectors but allow

higher density connectivity.

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Castellated Hole Design

Here are some key considerations when designing castellated holes in a

PCB:

Layer Connection

 Castellations normally connect the outer layer to the first inner

layer. But they can also link any two other adjacent layers.

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Hole Size

 Typical diameters are 0.3mm to 0.75mm to match adjacent via/hole

sizes.

Hole Spacing

 Center-to-center distance between castellations is usually 0.8mm to

1mm.

Pad Size

 Annular ring pad diameter around each hole is slightly larger than

hole.

Number of Rows

 Often, two parallel rows of staggered castellations are used.

Edge Margins

 A 1mm or more copper-free margin from board edge is typical.

Corner Shaping

 Castellations should avoid extending into board corners to prevent

cracking.

Mechanical Stability

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 Web of board material between holes should exceed 0.2mm for

rigidity.

PCB Fabrication Process

Castellated holes are fabricated along with other PCB holes:

1. Drilling

 During CAM, a compressed drill file is generated with normal and

castellated holes marked.

 The PCB manufacturer machines all holes in one pass using a

special bit.

2. Plating

 Electroless copper is deposited on the walls of all through holes and

castellations.

 This forms the conductive path between layers/externals pads.

3. Routing

 A V-shaped notch is cut into the edge where castellations are

located.

 This exposes the plated half-hole while isolating them from the

board edge.

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4. Outer Layer Finish

 Standard processes are used to pattern copper and apply solder

mask, legend, etc.

 Castellated pads are covered with solder mask for insulation.

This fabrication process requires precise drilling and routing but

otherwise follows standard PCB manufacturing techniques.

Applications of Castellated Holes

Castellated holes enable several unique PCB assembly possibilities:

Stacking Boards Vertically

 Boards can be stacked and interconnected without sockets or

headers.

 Aligned castellated pads on each board edge provide direct vertical

connections.

Edge Mounting Components

 Components can be mounted vertically or horizontally along the

PCB edge.

 Leads are soldered directly into exposed castellated pads.

Testing Points

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 Provides easy test access to internal signals from board edge.

 Can probe castellated pads for debugging and troubleshooting.

Board-to-Board Cableless Interconnect

 Enables high density board-to-board connections without cables.

 Aligned pads on matched castellated edges are joined to

interconnect boards.

Improved Thermal Performance

 Exposed pads along edge act like cooling fins to improve heat

dissipation.

Interposer Linkage

 Can solder boards to both sides of a central castellated interposer

board.

Probe Testing

 Allows probing board from edge for in-circuit testing during

manufacturing.

LGA (Land Grid Array) Sockets

 Some LGA sockets have castellated edges to engage with PCB.

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These examples demonstrate the versatility of castellated holes for

innovative PCB construction and integration techniques.

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Benefits of Castellated Holes

Castellated holes offer several advantages compared to other

board-to-board and external connection methods:

Higher Density

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 Castellations allow more I/O connections along a board edge than

possible with connectors. Hundreds of high-density signals can be

accessed through rows of staggered holes.

Lower Cost

 Eliminates need for mating connectors or cables between PCBs or

for test points.

Space Savings

 No connectors consume space on the surface or increase stack

height between vertically joined PCBs.

Design Flexibility

 Castellated holes can be placed anywhere along the edge for

routing convenience.

Reliability

 Robust plated holes with no moving parts or wear-out mechanisms.

Assembly Simplicity

 PCBs can be directly stacked and soldered together without

additional components.

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Performance

 Allows high-frequency signals with lower noise compared to cables

or connectors.

Serviceability

 Individual PCBs can be unstacked for repair instead of replacing

entire assembly.

Customization

 Holes can be sized and placed according to specific connection

requirements.

Comparison to Other Interconnects

Here is how castellated holes compare to some other PCB edge

connection methods:

Parameter Castellations Edge Connectors PCB Edge Contacts

Density Very High Moderate High
Cost Low High Moderate
Design Effort Moderate Low High
Signal Frequency High Moderate High
Flexibility Moderate Low High
Durability High Moderate Low
Repairability High Low Moderate

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So castellated holes provide a good combination of density, performance,

durability, cost and design flexibility compared to other interconnect

options.

Challenges of Castellated Holes

Some limitations to consider when planning to use castellated holes:

 Special drill/route fabrication equipment required. Not all PCB

manufacturers support this capability initially.

 Larger minimum board thickness required (1mm+) to accommodate

half-holes.

 Limited number of rows possible to maintain sufficient edge

webbing strength.

 May need edge reinforcements like chamfers or thickened region

for mechanical robustness.

 Inspection and repair of soldered castellations is challenging.

 Thermal expansion mismatch stresses connections during

temperature cycling.

With careful design and assembly, these concerns can usually be

addressed to utilize castellated holes effectively.

Conclusion

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Castellated holes provide a versatile technique to extend PCB layer

connections to the external edge for inter-board linking, stacking, probing

or component mounting. They enable dense vertical interconnects

between rigid boards without cables or connectors. With growing

applications in 5G communication, network systems, consumer products

and other high-speed vertical edge coupling requirements, usage of

castellated holes will continue increasing in PCB designs.

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Frequently Asked Questions

Can castellated holes be used on flex PCBs?

No, castellated holes are not recommended for flex PCBs as the rigid

protruding pads would restrict bending and worsen flex life performance.

They are only used on rigid boards.

What are the typical dimensions for a castellated hole?

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Common diameters range from 0.3 to 0.75 mm. Pad diameters are

~0.1mm larger than hole. Hole length into board is usually over 1mm.

Edge margins are above 1mm.

Can components be soldered horizontally onto castellated pads?

Yes, castellations allow mounting components

like resistors or capacitors horizontally along the PCB edge. Their leads are

soldered onto the exposed cylindrical pads.

How are castellated holes specified in PCB design?

Castellated holes are indicated on an additional fabrication layer in the

CAM/Gerber data. The compressed drill file also marks them as half-holes.

How many rows of staggered castellations are typical?

Most designs utilize one or two rows of staggered castellated holes. More

rows are possible but reduce edge material thickness affecting mechanical

stability.

Related Posts:

1. What are Castellated Pads?

2. Why Need Tooling Holes On PCB?

3. Soldering Castellations PCB Mounting Holes

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4. What is Countersink Holes in PCB ?

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