Thin PCBs—typically referring to boards with a thickness below 1.0 mm (commonly 0.6 mm, 0.4 mm, or even 0.2 mm)—are widely used in smartphones, wearable devices, aerospace, and advanced packaging applications due to their lightweight, slim, and flexible characteristics.

However, both their design and fabrication are far more challenging than standard PCBs.

Ⅰ. Design Guidelines for Thin PCBs

The most critical aspect of thin PCB design is maintaining mechanical stability to avoid deformation, warpage, or cracking.

1. Lamination Structure and Symmetry