Dielectric Dimension
Multilayer circuit board fabrication relies on the precise consolidation of prepreg and core layers during the lamination process. The pressed thickness represents the final height of a prepreg layer after it has been fully cured under temperature and pressure in the lamination press. It determines the spacing between adjacent copper trace layers, which is a factor in defining the characteristic impedance of signal lines.
Layup engineers calculate this thickness before production to ensure the board meets both mechanical and electrical design requirements.
Thickness Control
Resin flow during lamination is the primary variable affecting the final pressed thickness. When prepreg layers are squeezed under high pressure, the resin melts and flows to fill the gaps and voids around the copper patterns of the adjacent core layers. Consequently, the pressed thickness of the prepreg will be thinner over areas with high copper density and thicker over areas with low copper density.
Fabricators use empirical models and calculation tools to estimate this flow, taking into account the copper distribution and the resin percentage of the starting prepreg sheet.
Flow Analysis
Control of this parameter is necessary for maintaining consistent signal performance across the board. If the lamination process is not tightly controlled, the resulting thickness variation can cause impedance shifts that lead to signal reflections and timing errors. Board shops monitor this parameter by sectioning sample boards from each batch and measuring the layer heights under a microscope.