Based in Duluth, GA, Advanced Circuitry International manufactures complex Printed Circuit Boards, including RF/Microwave, antenna, large format, and multilayer PCBs. They offer rapid prototyping and assembly services for defense, aerospace, medical, and telecommunications. Capabilities include plated-thru structures up to 24″x102″.
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HDI PCB Manufacturers
Last updated: January 2026
This directory lists 85 hdi pcb manufacturers across the United States, from quick-turn prototype specialists to high-volume production facilities with advanced sequential lamination capabilities.
Buyers typically engage these manufacturers to solve critical problems related to device miniaturization, enhanced signal integrity for high-frequency applications, and robust thermal management in densely packed electronics. The need for advanced interconnection technologies like laser drilling for microvias and intricate build-up layers is often driven by demands for smaller form factors and higher functionality in consumer, medical, and aerospace industries.
The landscape of HDI manufacturers is quite diverse, ranging from smaller, agile shops excelling in rapid prototyping of complex stacked microvia designs, to large-scale operations focused on high-volume production requiring strict process control for boards with high layer counts and stringent impedance control. Some specialize in specific niches, such as flex-rigid HDI for wearable tech or those with ITAR compliance for defense applications, while others offer broad capabilities across various HDI complexities.
To ensure a smooth engagement, buyers should come prepared with fully defined stack-ups, detailed fabrication notes, specified material types (including Dk/Df requirements for high-frequency designs), and explicit impedance targets. Expect suppliers to thoroughly review your Design for Manufacturability (DFM) files and potentially request clarification on microvia structures, aspect ratios, and test methodologies, as these factors significantly influence both cost and manufacturability.
Company Directory
85 companies nationwide
Based in Santa Ana, CA, Almatron Electronics Inc. manufactures custom printed circuit boards. The company offers rigid, flex, and aluminum PCBs with no minimum order quantity. They provide quick turnarounds, typically in 2-3 weeks, with expedited options available for their clients.
Based in Elk Grove Village, IL, Amitron Corporation is a US PCB manufacturer established in 1985. They provide high-quality, quickturn printed circuit boards, including HDI with blind via technology and advanced thermal management. Amitron serves the medical, military, automotive, and consumer electronics industries.
American Standard Circuits (ASC) manufactures Ultra HDI, rigid, metal-backed/core, RF/microwave, flex, and rigid-flex PCBs for diverse industries. The company offers single-sided, double-sided, multilayer, and rigid-flex circuit boards, capable of producing Ultra-Fine Lines and Spaces down to 25 micron.
Based in Lakeville, MN, Automated Assembly specializes in flex circuit manufacturing. The company provides cutting-edge solutions and reliable production services for flexible circuit boards, especially for wearables. They directly provide specialized PCB manufacturing, offering expertise in advanced electronic components.
Bay Area Circuits, based in Fremont, CA, is a US manufacturer specializing in quick-turn printed circuit board fabrication, design, and assembly. Since 1975, the company has leveraged cutting-edge technology and intelligent automation to provide end-to-end PCB manufacturing services for customized boards, serving diverse industries.
Blind Buried Circuits, based in Stafford, TX, specializes in custom PCB manufacturing. They produce high-density interconnect (HDI) PCBs, rigid, flex, and semi-flex circuits, offering quick-turn prototypes and large volume production. This ISO and IPC certified Turnkey EMS provider serves diverse sectors including medical, automotive, and telecom.
Based in Carson, CA, ACME PCB Assembly is an ISO 9001:2015 certified electronic contract manufacturer. With over 30 years of experience, they provide comprehensive PCB assembly services, including SMT, BGA, Thru-Hole, and turnkey solutions. Their offerings extend to PCB fabrication, box builds, and design services for electronics.
Based in Santa Ana, CA, PARPRO Technologies is an ISO certified Electronics Manufacturing Services (EMS) supplier. They offer custom PCB assembly with advanced capabilities like fine pitch (0.3 mm), Micro BGAs, 01005 components, and PoP technologies. These services support high-density interconnect (HDI) PCBA, from prototype to volume production needs.
Candor Industries specializes in advanced PCB manufacturing, offering solutions for complex circuit board designs. They provide high-quality products including Aluminum, Ball Grid Array, Copper Core, Custom, and Flexible/Rigid-Flex PCBs. ISO 9001:2015 and CGRP certified, the company focuses on precision and efficient project delivery.
Circuit Tech Inc. manufactures printed circuit boards, focusing on quality, reliability, and durability for electronic assemblies. They specialize in advanced HDI Micro Via/Blind and Buried PCBs, alongside flex and rigid-flexible PCB needs. The company emphasizes continuous improvement in production processes and offers robust supply chain management to meet client requirements.
Based in Schaumburg, IL, Creative Hi-Tech directly manufactures advanced PCBs. They employ modern assembly technologies such as high aspect ratio plating, sequential build-up technology, resin plugging, and impedance control. The company provides comprehensive services for complex and high-density interconnect (HDI) printed circuit board manufacturing.
Based in Dallas, TX, Eagle Circuits provides complete in-house PCB solutions, including layout, fabrication, assembly, and testing. At their 18,000 sq ft USA facility, they deliver quick-turn prototypes to production runs, emphasizing quality and schedule control as an active IPC member.
Based in Bedford, MA, Epec specializes in the manufacturing of High-Density Interconnect (HDI) PCBs, a rapidly growing technology. Their HDI boards incorporate advanced features such as blind and buried vias. The company offers an online portal for instant quotes and 24/7 ordering of custom PCBs.
Based in Lancaster, PA, Etemco specializes in full turn-key PCB manufacturing services. They provide verified precision and comprehensive documentation for medical OEMs across Pennsylvania, New Jersey, Delaware, and Ohio, offering complete manufacturing solutions for complex circuit board requirements.
Excello Circuits, based in Anaheim, CA, manufactures advanced High-Density Interconnect (HDI) PCBs, including complex multilayer boards up to 24 layers. They provide a range of PCB solutions like rigid, flexible, and heavy copper, serving aerospace, medical, automotive, and communications sectors from design to production.
Based in Orange County, CA, Expert Assembly provides advanced electronics contract manufacturing services. They specialize in high-density interconnect (HDI) PCB fabrication and assembly, delivering solutions for higher component density and electrical performance. The company supports diverse OEM customers across Aerospace, Medical, and Industrial markets.
Based in Santa Clara, CA, Fineline-USA specializes in comprehensive PCB fabrication solutions, leveraging over 25 years of industry expertise. The company directly manufactures Rigid, Rigid-Flex, and Flex PCBs, offering a one-stop solution for diverse electronics applications.
Fineline Circuits & Technology Inc., based in Brea, CA, is an Electronic Manufacturing Service provider founded in 1978. They specialize in advanced Printed Circuit Board Fabrication, including rigid, flex, and rigid-flex PCBs. The company offers comprehensive design, assembly, functional testing, and box build services.
Fineline Circuits Inc., based in Feasterville, PA, manufactures single, double, and multi-layer printed circuit boards, offering up to 12 layers. With over 27 years of experience, they provide comprehensive PCB fabrication and assembly services. The company offers premium and expedited delivery options, assisting clients from design to fabrication.
Based in Irwindale, CA, Fine Pitch Electronic Assembly specializes in providing PCB and box build assemblies. Established in 1984, the company offers electronic assembly services for various industrial and commercial applications.
Based in Phoenix, AZ, Flex PCB specializes in high-quality, quick-turn prototype rigid-flex and flex PCB manufacturing. As a USA PCB supplier, it offers fully flexible printed circuit boards and high-density interconnect (HDI) PCBs, delivering reliable and high-performance circuits for various markets.
Based in Windsor, CT, Foxtronics EMS specializes in manufacturing high-performance rigid and HDI PCBAs with fine lines, microvias, and multilayer stackups. They provide precision PCB assembly services, box builds, and electronic systems for compact, high-speed electronics. Serving critical industries like aerospace, medical devices, and robotics.
Based in San Jose, CA, Gorilla Circuits is a USA printed circuit board manufacturer. They offer comprehensive turn-key PCB fabrication and assembly services. Certified to MIL-PRF-31032, MIL-PRF-55110, AS9100, and IPC Class 3, they serve critical Defense, Aerospace, IoT, and Robotics industries with high-quality PCB solutions.
Based in San Jose, CA, Green Circuits provides advanced PCB design, rapid prototyping, and quick-turn assembly services. They specialize in single, multi-layer flexible and rigid circuit boards, offering full-scale production. The company is ISO 9001, ITAR, and AS9100D certified.
Based in St. Petersburg, FL, HT Global Circuits, LLC manufactures high-quality printed circuit boards. With over 35 years of experience, they provide HDI, rigid, rigid-flex, flex, RF, and metal core PCBs. The company focuses on small to medium volume production, delivering competitive technology and strong support for electronic assemblies.
Based in Flower Mound, TX, Hughes Cain specializes in manufacturing advanced Rigid Flex and HDI boards up to 12 layers. Their capabilities include blind and buried vias, via on pad technology, and filled vias, providing high-density interconnect PCB solutions for various industries.
Based in San Marcos, CA, Hughes Circuits Inc. offers comprehensive PCB layout, fabrication, and assembly services. They specialize in high-reliability, leading-edge technologies, working with advanced materials, flex, and rigid-flex PCBs. Serving military, medical, and high-speed/RF markets, they provide quick-turn prototypes and low-volume production.
Insight PCB manufactures High-Density Interconnect (HDI) PCBs. The company specializes in producing interconnect PCBs with precision microvias, advanced lamination techniques, and designs optimized for superior signal integrity. They cater to industrial and commercial B2B customers requiring sophisticated printed circuit board solutions.
Based in Monroe, OH, Journey Electronics manufactures and అసెంబ్లీ custom electronic printed circuit boards. They specialize in SMT, through-hole, and high-density PCB fabrication and assembly services for prototypes and high-volume runs. The company operates under strict IPC-A-610, IPC-A-600, and ANSI/ESD S20.20-2021 quality standards.
Based in Austin, TX, Kodiak Assembly Solutions offers flexible electronic manufacturing services, including high-mix PCB assembly from prototype to high-volume production. They provide turnkey system integration, box build assembly, and SMT assembly for small components, serving high-reliability industries like IoT and RF communications. The company is ISO 9001:2015 and ITAR certified.
Based in Austin, TX, Laritech Inc. specializes in quick-turn Printed Circuit Board Assembly (PCBA) and prototyping, offering 1 to 2-day turnarounds. They provide comprehensive services including production, supply chain management, component procurement, and functional testing of complete units.
Levison Enterprises provides electronic manufacturing services, specializing in assembly for military, aerospace, medical devices, and food safety electronics. The company is AS9100, ISO 9001, and ISO 13485 certified. They also offer comprehensive turnkey electronic repair services for industrial and defense clients.
Lone Star Circuits is a Wylie, Texas-based company specializing in the manufacturing of Printed Circuit Boards. They provide a range of advanced PCB solutions, including capabilities in PTFE Multilayer bonding. The company focuses on delivering high-quality circuit board products.
Mega Plus PCB is a US-based manufacturer specializing in precision-engineered printed circuit boards. The company supplies high-quality PCBs for life-saving medical devices and various healthcare applications, serving the USA market.
Based in Milpitas, CA, Meritronics provides fast and efficient PCB design and production processes. The company specializes in manufacturing printed circuit boards for the consumer electronics industry. Their capabilities include producing High-Density Interconnect (HDI) PCBs, offering comprehensive solutions directly from their US facilities.
Murrietta Circuits, based in Anaheim, CA, operates a PCB manufacturing facility specializing in complex circuit board requirements. Equipped with automated machinery, the company produces high layer count boards, indicating capabilities in High-Density Interconnect (HDI) PCB manufacturing for diverse industrial applications.
Based in Irving, TX, NetVia Group is a US-based manufacturer of high-reliability advanced circuit boards, specializing in time-critical PCB solutions. They offer Controlled Impedance HDI PCBs, Flex & Rigid-Flex PCBs, and Microwave/RF PCBs for aerospace, military, medical, and commercial applications.
Based in San Jose, CA, Network PCB specializes in manufacturing and assembly of high-density interconnect (HDI) and complex multi-layer printed circuit boards. They offer high-volume production, rapid prototyping, design review, and component sourcing for diverse industries, leveraging over three decades of expertise.
Based in Mesa, CA, NPI Services specializes in the fabrication of various printed circuit board types, including Rigid, Rigid-Flex, HDI, and conventional PCBs. The company certifies that all finished products accurately meet specified customer requirements and design specifications.
Based in Schaumburg, IL, Journey Circuits INC provides high-quality, USA-based PCB manufacturing and assembly services. They specialize in advanced circuit board types including HDI PCB, Multi-Layer Flex PCB, High Speed Signal PCB, and Probe Card PCB. The company offers rapid prototyping and complete PCB solutions for various industrial applications.
Based in Southlake, TX, Advanced Circuits provides high-quality printed circuit board fabrication and assembly, specializing in high-density interconnect (HDI) PCBs. Their services cover prototyping to production, supporting complex designs for advanced components. The company holds ITAR, AS9100D/ISO9001:2015, and RoHS certifications.
PCB Power, based in Chatsworth, CA, directly manufactures high-quality PCBs. They offer fabrication for prototypes to large-scale production, employing advanced processes. The company also provides assembly and component sourcing, serving consumer electronics, medical, and industrial systems.
Based in Milpitas, CA, PCB Trace Technologies Inc specializes in manufacturing advanced circuit boards. The company directly produces flexible and rigid-flex PCBs, catering to complex electronic assembly needs for various industries.
PICA Manufacturing Solutions is an electronics manufacturing provider specializing in bare circuits, flexible printed circuits, rigid-flex circuits, and printed circuit boards. Based in Derry, NH, they offer engineer-driven solutions from design to delivery, focusing on quality and innovation. Their capabilities include metal core and ceramic PCBs, serving a diverse clientele.
Based in Santa Ana, CA, Pioneer Circuits manufactures and assembles flex, rigid-flex, and rigid circuit boards for demanding industrial, aerospace, and defense applications. They specialize in high layer-count and complex PCBAs, offering full-turnkey solutions from design through delivery with comprehensive quality control.
Based in Nutley, NJ, PNC Inc. is an experienced circuit board manufacturer providing PCB design, fabrication, and assembly. They specialize in high-reliability electronics for defense, medical, and high-frequency RF/Microwave industries, serving as the largest manufacturer in the Northeast.
Based in Houston, TX, PPSI is an ITAR registered, minority-certified manufacturer operating with an aerospace-certified quality management system. The company adheres to IPC 610 industry standards, demonstrating expertise in electronic assembly and quality control. PPSI provides high-quality, on-time manufacturing solutions for demanding industries, including aerospace.
Based in Dayton, OH, Projects Unlimited Inc. specializes in electronics manufacturing services, including circuit board assembly, cable & wiring, and box build integration. With over 50 years of experience, they adhere to advanced IPC Class 3 standards, ensuring superior quality and reliability for critical applications.
PWB America provides comprehensive, quick-turn solutions for PCB design, fabrication, and assembly. Serving diverse industries like telecom, semiconductor, aerospace, and medical devices, they cater to clients from startups to Fortune 500 companies. The company emphasizes rapid prototyping and utilizes a global network for flexible manufacturing options.
Based in Gardena, CA, Qual-Pro is an electronics contract manufacturer specializing in high-density PCB assembly and engineering. They provide comprehensive services from design and prototyping to full-scale production and rigorous testing. Established in 1971, the company holds ISO 9001, AS9100, and ISO 13485 certifications.
Based in Grand Prairie, TX, REYcomp provides advanced Printed Circuit Board Assembly manufacturing, specializing in miniaturization. Services include SMT, through-hole, wire harnesses, and complete box builds, moving products from prototype to market. They adhere to IPC-A-610 and AS9102 quality standards for electronic assemblies.
Rush Flex PCB manufactures flexible and rigid-flex PCBs from its USA facility in Milpitas, CA. The company handles both prototypes and large-volume production runs, specializing in High-Density Interconnect (HDI) PCBs. They provide comprehensive services from design to production with 24-hour tech support.
Based in Milpitas, CA, Rush PCB manufactures multilayer printed circuit boards, including rigid, rigid-flex, and flex types. They specialize in providing advanced High-Density Interconnect (HDI) PCB manufacturing services. The company offers comprehensive PCB solutions tailored for various electronic design requirements in the electronics industry.
Based in San Jose, CA, Sanmina Corporation manufactures printed circuit boards (PCBs) for mission-critical environments across defense, aerospace, and medical sectors. The company provides comprehensive PCB solutions and expands its manufacturing capabilities into data center infrastructure for cloud and AI.
Based in Romulus, MI, Saturn Electronics is a bare printed circuit board manufacturer. They offer advanced PCB technologies including fine lines, blind/buried vias, and via-in-pad, crucial for high-density interconnect (HDI) designs. Capabilities also span RF-Microwave, flexible/rigid-flex, and heavy copper boards.
Based in San Mateo, CA, SFCircuits is a US-based PCB manufacturer specializing in quick-turn prototypes and low-to-mid volume production. They offer a full range of PCB manufacturing services, including HDI, rigid, flex, and rigid-flex PCBs for various industries.
Silitronics specializes in advanced semiconductor and photonics packaging, offering high-precision design and advanced build-up substrate fabrication. The company provides wafer processing, optical alignment, and multi-chiplet SiP solutions for AI, HPC, and 6G networks, with capabilities including 12 micron line/space.
Based in Fremont, CA, Sonic Manufacturing Technologies provides comprehensive electronic manufacturing services. Specializing in advanced printed circuit board assembly and system integration, they manage projects from new product introduction to complete supply chain solutions, ensuring top-quality and efficient production for diverse electronic components.
Based in Santa Clara, CA, Surface Mount Solutions specializes in precision PCB assembly and electronics manufacturing. They provide quick-turn, standard, and full turnkey solutions, managing projects from prototype builds to full-scale production for aerospace, defense, and entertainment tech sectors.
SV Tronics is a company involved in consumer electronics manufacturing, particularly for devices like smartphones, tablets, and laptops that utilize HDI PCBs. They offer PCB Assembly services, indicating their direct involvement in the production and integration of high-density interconnect circuit boards for advanced electronic products.
Based in Anaheim, CA, Technotronix provides PCB manufacturing, assembly, and quick-turn prototyping services. They offer box-builds and value-added services like BGA assembly. Serving electronics, automotive, and medical industries, Technotronix uses sequential lamination for high-density interconnect (HDI) circuit board production.
ECMG is an electronic contract manufacturer based in St. Louis, MO. The company specializes in PCB assembly, including complex multi-layer and High-Density Interconnect (HDI) technology, box build, cabling, and testing. They serve diverse industries such as medical, telecommunications, automotive, industrial, and defense, providing comprehensive manufacturing solutions.
Based in Anaheim, CA, Transline Technology Inc. specializes in RF, Microwave, and mmWave PCB fabrication. With over three decades of experience, the company provides high-quality printed circuit board manufacturing services for innovative design engineers. They are a renowned PCB and microwave manufacturer.
TTM Technologies, Inc. manufactures advanced printed circuit boards, specializing in HDI PCBs, microvia, and high density interconnect products. The company provides PCB and connectivity solutions for demanding B2B applications across computing, industrial, medical, 5G, aerospace & defense, networking, and automotive sectors globally.
Based in Arlington, TX, Texas Circuitry is a printed circuit board manufacturer. They specialize in fabricating rigid single-sided, double-sided, and multi-layer PCBs, handling jobs up to 16 layers. The company provides both prototype and production services, utilizing state-of-the-art equipment and an experienced staff.
Based in West Seneca, NY, Via Technology offers comprehensive PC board layout, design, and assembly solutions. They specialize in electronic design, prototyping, and production for diverse sectors including aerospace, military, industrial, commercial, medical, and scientific applications, developing custom hardware and software electronics.
Based in Warwick, RI, VR Industries specializes in comprehensive printed circuit board manufacturing and assembly services. They offer SMT and through-hole PCB assembly, adhering to rigorous IPC Class 3 and stringent medical/military standards, supporting reshoring initiatives.
Based in San Jose, CA, VSE provides US-manufactured electronic products, specializing in custom PCBA, including HDI, multilayer, rigid-flex, and high-speed PCB assembly. The company offers comprehensive design, engineering, procurement, and testing services for industries such as medical, semiconductor, aerospace, and automotive.
Based in Brea, CA, Winonics manufactures advanced technology PCBs, offering comprehensive circuit board solutions. The company utilizes a patented additive process and holds Lockheed RMS approval for rigid printed wiring boards, meeting IPC-6011 and 6012 specifications. They specialize in designs involving sequential laminations and stacked PCBs.
Based in Fremont, CA, Cofan Thermal PCB specializes in the design and manufacturing of PCBs and multilayer MCPCBs. With over 30 years of experience, the company provides cutting-edge thermal management solutions, serving industrial and commercial B2B customers directly from their US facilities.
Based in Anaheim, CA, POE PCBA manufactures small to medium volume PCBs and PCBAs. With over 20 years of OEM and EMS experience, they offer turn-key services from manufacturing and component sourcing to assembly and testing. The company provides fast turnarounds and adheres to ISO, RoHS, and UL standards.
Based in Austin, Texas, Rapid PCB, LLC specializes in the manufacturing of printed circuit boards. The company provides engineering support for various PCB applications, serving industrial and commercial clients from its Texas facilities.
Spectra-Tech Manufacturing Inc., based in Batavia, OH, provides high-quality Electronic Manufacturing Services (EMS). Specializing in PCB manufacturing and assembly, they manage all components for their B2B customers. The company focuses on long-term partnerships, emphasizing quality and compliance in its production processes.
Based in Aurora, CO, Advanced PCB is an American manufacturer offering comprehensive PCB design, manufacturing, and assembly services. They specialize in high-density interconnect (HDI) PCBs and provide quick-turn solutions for industries including defense, medical technology, and telecommunications.
Alpha Circuit Corp. specializes in high-quality printed circuit board (PCB) manufacturing. Based in Elmhurst, IL, the company offers a comprehensive range of PCB solutions, including HDI, Rigid-Flex, and High-Frequency PCBs. They provide reliable and efficient production for various industrial applications.
Based in Calumet, MI, Calumet Electronics manufactures highly integrated HDI PCBs and organic substrates. The company provides advanced multi-layer bridge plating and sequential lamination, utilizing materials like polyimide/FR4. They serve demanding sectors including aerospace, DoD, and medical device industries.
CEMFG specializes in comprehensive services, including intricate circuit board assembly. The company also provides advanced machine programming and execution, offering manufacturing solutions for various industries. Based in Orange County, CA, they serve clients with their in-house capabilities.
Based in Fredericksburg, VA, FTG Circuits specializes in manufacturing high-reliability and complex PCBs for aerospace and defense. They offer a range of products including Semi Additive Process (SAP) HDI, high-temperature rigid-flex, RF products, and thermal management solutions.
Midwest Printed Circuit Services, Inc. is a U.S. Printed Circuit Board (PCB) supplier based in Round Lake Beach, IL. Operating 100% American-made fabrication facilities, they provide interconnection solutions. The company offers advanced PCB features, including high-density interconnect (HDI) suitable for compact consumer electronics designs.
NPI Technologies is a contract-based electronic manufacturing company located in Richardson, TX. They specialize in creating the internals for various devices, offering PCB manufacturing services at any volume. The company provides essential components for their clients' electronic products, focusing on reliable and scalable production.
Based in Eatontown, NJ, PCB Technologies specializes in manufacturing High-Density Interconnect (HDI) PCBs. The company provides advanced PCB solutions, assembly, and iNPACK advanced IC packaging. They serve demanding industries like aerospace, defense, automotive, medical electronics, and semiconductor, focusing on high functionality.
Sierra Circuits, established in 1986, is a US-based manufacturer specializing in quick-turn, high-quality HDI printed circuit boards and assemblies. They provide American-made PCB prototypes, offering precision manufacturing and instant online quotes directly from their facilities.
RBB Systems provides specialized manufacturing solutions for complex printed circuit board assemblies (PCBA) and control panel projects. Based in Wooster, OH, the company assists manufacturers by streamlining the production of intricate electronic components, helping to eliminate challenges in advanced industrial applications.
Benchmark delivers full product lifecycle solutions, spanning design engineering, technology building blocks, and advanced manufacturing for electronics. As a leading EMS provider, their capabilities include the production and assembly of high-density interconnect (HDI) PCBs, alongside aftermarket services. They support diverse industries with integrated manufacturing solutions.
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How to Choose a Company
- Verify microvia drilling and plating expertise: Insist on seeing process capability data for their smallest specified microvia diameter and aspect ratio, especially for filled and capped via-in-pad structures, to ensure consistent plating quality and long-term reliability.
- Assess sequential lamination proficiency: Confirm their ability to precisely align and laminate multiple build-up layers without introducing excessive warpage or registration errors, particularly critical for high layer count HDI boards requiring tight annular rings and buried vias.
- Scrutinize impedance control capabilities: Demand specific examples and measurement reports for their impedance control processes, including their tolerance capabilities for various trace geometries and dielectric materials (e.g., ±5% on 50-ohm lines at 3 mil trace/space).
- Confirm relevant certifications and compliance: For medical devices or aerospace, require specific certifications like ISO 13485, AS9100, or ITAR registration, alongside IPC-6012 Class 3 adherence, verifying they can meet stringent performance and reliability standards.
- Red Flag - Over-promising on exotic materials or extremely tight tolerances without justification: Be wary of manufacturers who claim they can meet aggressive Dk/Df material specs or sub-2 mil line/space requirements for high-volume production without presenting clear process control data or reference projects, as this often leads to costly re-spins.
- Evaluate their DFM (Design for Manufacturability) collaboration: A good HDI manufacturer will proactively engage in DFM discussions early, identifying potential issues with pad-on-via structures, copper distribution, or thermal management strategies before fabrication begins, saving time and cost.
Frequently Asked Questions
What minimum microvia size can I realistically expect from most reputable HDI manufacturers?
While some cutting-edge facilities might quote down to 50µm (2 mil), a more widely achievable and reliable minimum for most established HDI manufacturers in volume production is typically 75µm (3 mil) laser-drilled microvias. Pushing below this often incurs significant cost increases, reduced yields, and requires extensive DFM collaboration, so always clarify their proven process capability (Cpk) at your desired dimension.
How does sequential lamination impact lead time and cost for HDI boards?
Sequential lamination is a critical, multi-stage process where dielectric layers and copper foils are added and cured incrementally, with drilling and plating steps repeated after each "build-up" sequence. This significantly adds to both lead time and cost compared to standard multilayer PCBs, due to increased process steps, material handling, and the need for highly precise registration at each stage. Boards with more build-up layers (e.g., 2+N+2) will naturally be more expensive and take longer.
What are the key differences in DFM considerations for HDI vs. standard multilayer PCBs?
For HDI, DFM focuses much more intensely on microvia structures (stacked, staggered, blind, buried), aspect ratios, annular ring reliability, pad-on-via limitations, and sequential lamination sequence. You must also consider material choices carefully for thermal expansion and signal integrity, as well as ensure balanced copper distribution across layers to prevent warpage during the multi-stage lamination cycles. Standard multilayer DFM is more concerned with conventional drilling and basic layer stack-up.
When should I consider a manufacturer specializing in flex-rigid HDI?
You should seek out flex-rigid HDI specialists when your design requires a combination of high-density interconnects, extreme miniaturization, dynamic bending, or specific form factors that rigid-only boards cannot achieve. Common applications include medical implants, advanced wearables, or compact aerospace electronics where space is at a premium and a flexible section needs to integrate complex HDI features. These manufacturers have unique expertise in flexible dielectric materials and specialized processing to handle both rigid and flexible sections in the same board.
What questions should I ask about a manufacturer's CAF mitigation strategies?
For long-term reliability in humid or high-voltage environments, ask about their specific materials (e.g., low-CAF resins), drilling parameters (especially for closely spaced holes), hole cleaning processes (e.g., plasma etch effectiveness), and moisture absorption controls during fabrication. Also, inquire about their internal testing for CAF resistance (e.g., using IPC-TM-650 test methods or proprietary accelerated stress tests) to ensure their processes are robust against this insidious failure mechanism.