Standard PCB Thickness Guide

PCB thickness is a critical design decision affecting mechanical strength, flexibility, component compatibility, and manufacturing costs. Understanding standard options helps you choose the right thickness for your application.

Common PCB Thicknesses

The industry offers several standard thicknesses. Using standard sizes reduces cost and lead time.

Thickness (mm)	Thickness (inches)	Common Use
0.2mm	0.008"	Ultra-thin flex
0.4mm	0.016"	Thin devices, cards
0.6mm	0.024"	SIM cards, thin electronics
0.8mm	0.031"	Compact devices
1.0mm	0.039"	Tablets, thin laptops
1.2mm	0.047"	General electronics
1.6mm	0.063"	Standard (most common)
2.0mm	0.079"	Heavy components
2.4mm	0.094"	High rigidity needs
3.2mm	0.126"	Specialized applications

The 1.6mm Standard

1.6mm (0.063 inches) is the most common PCB thickness worldwide. This became the standard for several reasons:

• Compatible with standard edge connectors
• Good balance of rigidity and weight
• Suitable for most component types
• Widely available, lowest cost
• Works with standard panel mounting hardware

When to Use Thinner Boards

0.2mm - 0.4mm: Ultra-thin applications like flex PCBs, RFID tags, and specialized sensors. Requires careful handling.

0.4mm - 0.8mm: Smart cards, thin wearables, compact IoT devices, thin consumer electronics.

0.8mm - 1.2mm: Tablets, smartphones, thin laptops, space-constrained applications.

Advantages of Thin PCBs

• Reduced weight
• Smaller overall product size
• Better thermal performance in some cases
• Allows tighter assembly spacing

Disadvantages

• More prone to warping
• Harder to handle during assembly
• Limited connector options
• May not support heavy components

When to Use Thicker Boards

2.0mm - 2.4mm: Heavy connectors, power electronics, high-vibration environments.

2.4mm - 3.2mm: Military/aerospace applications, high-reliability systems, specialized requirements.

Advantages of Thick PCBs

• Excellent mechanical stability
• Supports heavy components
• Better for high-vibration environments
• More robust during handling

Disadvantages

• Increased weight
• Higher material cost
• Deeper drilling required
• May require special tooling

Factors Affecting Thickness Choice

Connector Requirements: Many connectors require specific board thicknesses. Check datasheets before specifying.

Component Weight: Heavy components (transformers, large connectors) need thicker boards for support.

Layer Count: Multi-layer boards need sufficient thickness for copper and prepreg layers.

Enclosure Constraints: The PCB must fit within the product housing.

Impedance Control: Controlled impedance designs may require specific thicknesses.

Flex Requirements: Flexible portions need thin material.

Manufacturing Considerations

• Non-standard thicknesses increase cost and lead time
• Very thin boards may require special handling
• Very thick boards may need specialized drilling equipment
• Standard 1.6mm offers the fastest turnaround and lowest cost

Conclusion

Choose 1.6mm for general applications—it's the most cost-effective and widely compatible option. Use thinner boards only when space constraints demand it, and thicker boards when mechanical requirements justify the added cost.