Kappa 438 2-Layer PCB built on 60mil Core laminates , 1.6mm Thickness with ENIG Finish using in Carrier Grade WiFi

Kappa 438 PCB: 2-Layer, 60mil Core, 1.6mm Thickness with ENIG Finish

(All PCBs are custom-manufactured. Reference images and parameters may vary based on your design requirements.)

Overview of Kappa 438 PCB

The Kappa 438 PCB is a 2-layer rigid PCB designed for high-frequency and RF applications requiring better performance than traditional FR-4 materials while maintaining compatibility with standard manufacturing processes. Built with Rogers Kappa 438 laminates, this PCB features a 60mil (1.524mm) core and a finished thickness of 1.6mm, providing low loss, stable dielectric properties, and high reliability.

The Electroless Nickel and Immersion Gold (ENIG) surface finish, combined with a black silkscreen on the top layer, ensures excellent solderability, corrosion resistance, and a professional aesthetic. With a dielectric constant (Dk) of 4.38, Kappa 438 laminates are tailored to FR-4 industry norms, making it easy to migrate existing FR-4 designs to this higher-performing material.

PCB Construction Details

PCB Stackup

Introduction to Kappa 438 Material

The Rogers Kappa 438 laminates are glass-reinforced hydrocarbon ceramic systems designed for high-frequency applications. These laminates offer a dielectric constant (Dk) of 4.38, low dissipation factor, and thermal stability, making them a versatile alternative to FR-4 in applications requiring improved electrical performance. They are fully compatible with standard FR-4 manufacturing processes, ensuring cost-effective fabrication and design flexibility.

Key Features of Kappa 438

• Dielectric Constant (Dk): 4.38, tailored to match FR-4 industry norms.
• Dissipation Factor: Low at 0.0038 for minimal signal loss.
• Thermal Coefficient of Dk: -21 ppm/°C for stable performance across temperature ranges (-50°C to 150°C).
• CTE (Coefficient of Thermal Expansion):
• X-axis: 42 ppm/°C.
• High Tg > 280°C ensures reliability during soldering.
• UL-94 V0 Certified: Flame-retardant for added safety.

Benefits of Kappa 438

• Ease of Manufacturing: Fully compatible with FR-4 processes for cost-effective production.
• Consistent Performance: Tight Dk and thickness tolerances ensure reliable circuit behavior.
• Low Signal Loss: High-frequency performance with reduced insertion loss.
• Improved Flexibility: Supports design upgrades from FR-4 without significant modifications.

Applications

1. Carrier Grade WiFi: Ensures high performance in wireless communication systems.
2. Small Cell and Distributed Antenna Systems (DAS): Reliable for telecom infrastructure.
3. Vehicle-to-Vehicle Communications (V2X): Critical for autonomous and connected vehicles.
4. Internet of Things (IoT): Suitable for smart home devices and wireless metering systems.
5. Phased Array Antennas: Stable performance in radar and RF applications.

Conclusion

The Kappa 438 2-layer PCB is a high-performance, cost-effective solution for RF, microwave, and high-frequency designs. With its 60mil Kappa 438 core, ENIG finish, and black silkscreen, this PCB combines low loss, thermal stability, and ease of manufacturability.

Engineered to meet IPC-Class-2 standards and available worldwide, the Kappa 438 PCB is the perfect choice for engineers upgrading FR-4 designs to achieve better electrical performance for advanced applications like carrier-grade WiFi, IoT devices, and automotive communications.