What is Teflon PCB and how to manufacture

What is Teflon PCB and how to manufacture

Worried about your high-temperature electronic projects?

Teflon PCB is a worthwhile solution to this problem because of its low CTE, high TG, and non-viscous nature. Its useful features and advantages make it a dependable replacement for FR4 in the PCB world.

As a leading PCB manufacturer in China, we will share the ins and outs of this PCB and its manufacturing which will be a great help to you. Let’s make a move.

Table of Contents

What is Teflon PCB?

Teflon PCB is a special kind of circuit board that is manufactured through Teflon material. Its principal ingredient is Poly Tetra Fluoro Ethylene (PTFE) which has a non-sticky nature with an inert molecular structure. Teflon PCB Teflon materials with the Dupont trademark have particular demand in the communication industry because of their electrical and thermal properties.

What is the material of Teflon PCB?

Teflon PCB Materials

Along with Teflon, Teflon PCB consists of the following materials:
●CEM (Composite Epoxy Material)
○CEM-1 (TG-122°C)
○CEM-2 (TG-125°C)
○CEM-3 (TG-125°C)
●Epoxy Materials (Reinforced by Glass)
●RF-35 (Laminate with organic ceramic)
●G-10 (Fiberglass)

Features and advantages of Teflon PCBs

Teflon PCB offers outstanding advantages with its unique features that you can only enjoy with Teflon.

Dielectric Constant2.94 (Z-Axis)
Dissipation Factor0.0012
CTE24 (Z-Axis)
Thermal Coefficient12 ppm/C
Moisture Absorption0.02%
Tensile Modulus828 MPa
FlammabilityV-O (UL-94 Testing)
Decomposition Temperature (TD)500 °CTGA
Surface Resistivity10^7 Mohm

Its notable benefits are:

Low dielectric constant
Teflon has a DK value of around 2.94 at 10GHz frequency. Such a low DK ensures its presence in high-frequency applications.

High chemical resistance
Teflon PCB is less-corrosive and superbly durable because of being highly chemically resistive.

Low CTE and high TG

Teflon PCB with High TG and Low CTEIts low CTE (Coefficient of Thermal Expansion) and high TG (Glass Transition Temperature) keep it compatible with high-temperature and high-power applications.

Low dissipation factor
As the dissipation factor indicates loss in signal propagation, Teflon is no doubt a useful PCB material in high-speed signal transmission systems.

Improved flammability
Teflon is a common ingredient in cooking materials because of its high flame resistance. Its high transition temperature and superior flexibility make it applicable in high-temperature electronic applications.

Low frictional coefficient
Teflon offers a smooth surface with non-stick properties. That’s why its frictional coefficient is very low. This feature indicates Teflon’s high flexibility and durability.

Applications of Teflon PCBs

As Teflon PCB ensures high durability and advanced functionality with improved density, it is used in numerous electronic applications of versatile industries. The most notable applications of this PCB include:
Communication industry: Mobile, Routers, Antenna, VHF (Very High Frequency) Radio. Aircraft instruments, Microwave

Electronic application: Power amplifier, Transformers

Medical industry: Diagnosis equipment, wearable monitoring device, Automated surgery system, imaging equipment

Industrial application: Automotive, Aerospace, Military

Others: Space equipment, Printers.

Teflon PCB manufacturing

Manufacturing of a Teflon PCB is the combination of a series of works that are correlated to each other. As the processing of Teflon materials isn’t the same as FR4 or CEM, you need to pay attention to each step to get the best outcome.

Let’s have a look at the most noteworthy steps of Teflon circuit board manufacturing.

Preparation of PCB surface
Here, manufacturers have to prepare a substrate surface so that they can perform the metalization and layer formation properly.

As Teflon is a soft material, you can’t use rough equipment that deforms this material during fabrication.

For example, bristles, composite brushes, pumice scrubbers, etc are not good choices for the surface preparation of Teflon circuit boards. But these products are very common in PCB manufacturing containing materials except Teflon. So what’s the solution to this case?

Manufacturers use Sodium etchants and plasma gas most of the time. Do you know why?
Sodium etchants are Halogen-free (especially Fluorine). That’s why these etchants can extend the hold time of these PCB materials after processing. You need to rinse Teflon with water and Alcohol after picking it out from the Sodium solution.

Besides, plasma gases are also dependable. These gases can be recycled through Hydrogen gas which has a positive impact on the manufacturing cost. This process is suitable for metalization, layering, and marking.

Use of solder mask
The application of PCB solder masks is a crucial part of manufacturing. You need to apply this within 12 hours of Sodium etching. Besides, you must make sure that there is no moisture absorption while using a solder mask.

This step is necessary to make sure that the drilled holes are precise and that there is no remaining Teflon in the holes. But how?

Here, manufacturers use a sharp drill with a high chip load and slow-pace feeding. As Teflon has improved rigidity with a low CTE, there is no need to apply too much stress during drilling.

Copper plating
It is highly recommended to use plated copper having a high tensile strength so that the possibility of pad lifting and barrel cracking decreases to a certain degree.

Besides, copper cladding with high ductility copper keeps Teflon away from blistering.

Lamination of materials
Teflon PCB lamination is performed under almost 370°C temperature and 450-500 PSI pressure. You don’t need to use bonding films in this way.

You can keep the operating temperature at 120-215°C by using bonding films. But, then you need to apply Oxide pretreatment that is similar to the lamination of FR4 materials.

Teflon PCB Manufacturing

As Teflon is a soft-natured PCB material, you must keep it safe from mechanical and thermal pressures. Most noteworthy, store Teflon PCBs in a dry and cold place that is free from oxidation and chemical contamination.

Do you know how to produce the prototype of Teflon PCB? Here are the basic steps for your convenience:

PCB design
The very first step is the designing of the Teflon PCB prototype. You can use design software like Altium Designer, KiCAD, etc, and stencil to create a perfect prototype design.

Material selection
The next step is selecting the rightest base material for the prototype. Recently, plastic materials have become very popular in this case. Remember, Teflon is not the base material of this circuit board.

Design testing
In this step, component placement and connections in the design are checked through a simulation.  

Here, manufacturers detect bugs and faulty connections in the prototypes and resolve these issues to deliver a flawless design.

A prototype board is made in this stage.

Functional test
In the end, a functional test is run to check its functionality and find any minute bugs which were ignored earlier.

After completing these steps, the manufacturer sends the prototype Teflon circuit board for final production.

Costs of Teflon PCBs

Teflon PCB consists of some high-quality materials which you can use this board for special purposes and different conditions. But this property increases the production cost of Teflon circuit boards, as well.

Compared to other PCB materials like FR4, CEM, etc, PTFE is a little bit more expensive. That’s why its cost rises.

Along with materials, some other factors have an impact on the cost of Teflon PCB. Such as-
●Number of layers
●Panel size
●Component sourcing
●Manufacturing process (Drilling, Surface Finish, Etching, Plating, etc)
●Lead time
●Testing type and equipment

Despite its comparatively high cost, the Teflon circuit board ensures higher functionality and durability which can make a balance for your project in the long run.

How to choose a good Teflon PCB manufacturer?

Teflon PCB manufacturer

Manufacturers play a vital role in any kind of PCB production. But which considerations are crucial to make a good choice in the case of a Teflon PCB manufacturer?

Let’s check:
●Long-term experience with credibility
●Technical expertise
●Professional technicians with equipment facility
●Minimum lead time
●Customization facility
●Reliable material sourcing
●Certification from reputed organizations like IPC, CE, etc.
●Professional customer and sales service.
●Affordable price

Teflon PCB is a special kind of circuit board that is manufactured through Teflon material. Its principal ingredient is Poly Tetra Fluoro Ethylene (PTFE) which has a non-sticky nature with an inert molecular structure.

  • Low dielectric constant
  • High chemical resistance
  • Low CTE and high TG
  • Low dissipation factor
  • Improved flammability
  • Low frictional coefficient
  • Communication industry
  • Electronic application
  • Medical industry
  • Industrial application, etc

Final words

Teflon PCB can improve the quality and functionality of your electronic goods as per your requirement. As technology upgrades day by day rapidly, its demand is also increasing. That’s why you need to choose the manufacturer wisely.

IBE offers one-stop solution to PCB manufacturing with great efficiency. Get in touch with us to enjoy a faultless PCBA service.

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