Halogen-Free PCB Manufacturing and Assembly at One-Stop
At Mars PCB, we are committed to sustainable manufacturing practices, which is why we provide high-quality, halogen-free printed circuit boards (PCBs). As the global demand for eco-friendly products continues to grow, our halogen-free PCBs meet stringent environmental standards, ensuring compliance with regulations while supporting customers who prioritize sustainable solutions for their electronic products.
Many companies use printed circuit boards (PCBs) in their products, but the materials used might not always be what you expect. For years, some PCBs contained halogens, but these elements have since been banned in many regions due to their environmental and health impacts. This guide explains why halogen-free PCBs are essential for your projects and how to identify the right materials for your needs.
What is a Halogen-free PCB?
Halogen-free PCBs are made with copper-clad laminate that contains minimal or no halogen elements. Specifically, according to the ES-01-2003 standard from the Japan Circuit Association (JPCA), these boards contain less than 0.09% by weight of halogens like bromine or chlorine. This makes them an environmentally safer alternative to traditional flame-retardant materials.
What Does Halogen-Free Mean for PCB/PCBA
For printed circuit boards, halogen-free means no halogen elements are present in the PCB materials or the entire manufacturing process.
Halogens include fluorine (F), chlorine (Cl), bromine (Br), iodine (I), and astatine (At). They are used as flame retardants but pose environmental and health risks.
Halogen-free requires PCBs, PCBAs, wiring cables, enclosures, and all parts of an electronic product to have less than 900 PPM of Cl or Br and under 1500 PPM of total halogens.
While not mandatory under REACH or RoHS directives, halogen-free PCBs support the green initiative trend.
Many regions, including the UK and several US states, are banning halogen-containing products. For example, most halogen lamps are now prohibited from sale.
PCB Halogen-Free Measurements
Halogen-free involves comprehensive measures, covering materials and the production process. Mars PCB ensures halogen-free standards through strict quality control from materials to packaging.
Mars PCB sources only halogen-free PCB laminates. All our suppliers meet our strict strategy and service requirements.
Our purchasing team ensures all materials are halogen-free and comply with PCB legislation. We provide customers with RoHS and halogen-free SGS test reports and MSDS composition lists.
All halogen-free materials from suppliers are labeled accordingly. Mars PCB verifies each supplier's Certificate of Conformity (COC) and tests every material batch for halogen-free standards.
Each halogen-free order is produced separately. Different production areas prevent material mixing to maintain halogen-free integrity.
We label halogen-free PCBs as per customer requirements. If no specific instructions are given, we mark the outer box with "HF."
Halogen-free PCB laminates and materials are stored in designated areas to avoid mixing with non-halogen-free items.
Halogen-Free PCBs
The halogen-free PCB/PCBA manufacturing process at Mars PCB is identical to standard processes, with additional strict management for halogen-free standards in materials and production.
In our halogen-free PCBs, phosphorus (P) and/or nitrogen (N)-based flame retardants replace halogen-based ones.
Advantages of Halogen-Free PCBs:
Halogen-free PCBs do not release toxic smoke when exposed to fire or during recycling.
Lower thermal expansion coefficients (CTE), longer delamination times (T-260/288), and higher thermal decomposition temperatures (Td).
Lower water absorption and superior thermal stability compared to halogen-based PCBs due to nitrogen-phosphorus resin.
Halogen-Free PCB Manufacturing Capabilities
Specifications | Mars PCB’s Halogen-Free PCB Capabilities |
PCB layer quantity | 1 to 68 (no layer limit) |
Halogen-free standards | IEC 61249-2-21, JS709C |
Turnaround time | 8 hours to 3 weeks |
Halogen-free PCB laminates | S1150G,S1170G, S7045G,S7439G,Isola DE156,IT150GXTC, IT-170GTTC,TU747HF,TU862HF，TU862T,TU883,EM285,EM370(D)，EM526 |
Halogen-free PCB substrate | FR4, aluminum, Teflon, ceramic, polyimide, copper |
PCB thickness | 0.15mm to 3.2mm |
PCB copper thickness | 1/3oz to 6oz |
Halogen-free FR4 Tg | 135℃, 150℃, 160℃, 170℃, 180℃, 185℃ |
Min. trace width/space | 1.6mil/1.6mil |
HDI stack-up | 1+N+1, 2+N+2, 3+N+3, 4+N+4 |
Surface finish | OSP, immersion silver, immersion gold, ENIG, immersion tin |
Why Were Halogens Banned in PCBs?
Halogens, including chlorine, bromine, fluorine, and iodine, have historically been used in PCBs for their flame-retardant properties. However, when burned, halogenated compounds can release toxic fumes that are harmful to both the environment and human health. Studies have shown that these gases can be carcinogenic, leading to bans in regions like the European Union and China.
Substances such as polybrominated diphenyl ethers (PBDE) and polybrominated biphenyls (PBB) are examples of halogen-based flame retardants that are no longer used in PCB production due to their toxic nature.
How Do Halogen-free PCBs Maintain Fire Resistance?
Halogen-free PCBs are still capable of being fire-resistant. While halogen-based flame retardants were traditionally used for their fire-resistance properties, alternative materials like ceramics, metal substrates, and phosphorus-based retardants offer a safer, non-toxic solution. These materials form a protective carbonized layer during combustion, which prevents further burning and helps maintain structural integrity.
How to Identify Halogen-free PCB Materials?
To determine whether a PCB is truly halogen-free, it’s important to understand the limits set by international standards. The International Electrotechnical Commission (IEC) defines halogen-free as having:
- Less than 900 ppm of bromine and chlorine.
- No more than 1500 ppm of total halogen content.
By adhering to these guidelines, you can ensure that your PCB materials are both safe and compliant with global regulations.
Halogen-free PCB Materials at Mars PCB
At Mars PCB, we offer a variety of halogen-free materials, including:
Halogen-free FR4 Materials: Our FR4 materials come from trusted suppliers like Ventec, ShengYi, and ITEQ.
Metal Substrates: We provide copper and aluminum-based substrates that are naturally non-toxic and flame-resistant.
Solder Mask Inks: We use halogen-free solder mask inks to ensure that your PCBs meet the highest environmental standards.
Challenges in Designing Halogen-free PCBs
Designing halogen-free PCBs comes with some unique challenges. These materials may require more power for drilling due to their higher mechanical strength. Additionally, they often need higher temperatures during reflow soldering, as well as careful management during the assembly process to prevent resistance issues.
Advantages of Halogen-free PCBs
Halogen-free PCBs are still capable of being fire-resistant. While halogen-based flame retardants were traditionally used for their fire-resistance properties, alternative materials like ceramics, metal substrates, and phosphorus-based retardants offer a safer, non-toxic solution. These materials form a protective carbonized layer during combustion, which prevents further burning and helps maintain structural integrity.
The benefits of halogen-free PCBs include:
Better Electrical Insulation: Halogen-free boards offer superior insulation properties compared to halogen-based products.
Lower Thermal Expansion: These boards maintain stability under temperature fluctuations.
Higher Glass Transition Temperature: With a higher glass transition point, these PCBs can handle more demanding applications.
Safer for Disposal: Halogen-free PCBs do not release harmful substances when disposed of, making them environmentally friendly.
Improved Moisture Resistance: These PCBs absorb less moisture, leading to better long-term performance.
Applications of Halogen-Free PCBs
- Automotive electronics and communication equipment
- Computers, tablets, smartphones
- Electronic game machines, VCRs
- DC/DC converters
- LED lamps, display screens
Why Choose Mars PCB for Halogen-free PCB Manufacturing?
At Mars PCB, we are leaders in the PCB manufacturing industry, offering halogen-free solutions that meet the highest performance standards. Our expert team uses only the best materials and follows rigorous quality control processes to deliver reliable, environmentally friendly PCBs that meet your exact specifications.
Our halogen-free PCBs are ideal for industries such as communication, automotive, medical, and industrial applications, where safety, compliance, and performance are paramount. Reach out to us today to discuss your project and request a quote.
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