KKPCB Success Story: Robotic Servo Drive Module PCBA
—Ultra-High-Density Design & Thermal Management for Compact Servo Systems
1. Customer Requirements
- Application: Industrial robotic joint drive control
- Key Challenges:
- Integrate 16-channel PWM control + current sampling within 80mm × 60mm
- Excessive MOSFET temperature rise (>30°C @20A), causing throttling
- Compliance with IEC 61000-6-4 (Industrial EMC Standard)
2. KKPCB Innovative Solution
（1）Ultra-High-Density Interconnect Design
- 10-layer any-layer HDI (1+N+1 stackup), 0.1mm laser microvias, enabling 5μm trace/space
- Hybrid Rigid-Flex: Critical signal layers with 2oz copper for lower impedance, 50% higher routing density
（2）Advanced Thermal Management
- Localized Aluminum Substrate: Embedded under MOSFETs (6 zones), 0.8°C/W thermal resistance
- 3D Thermal Simulation: Optimized via Flotherm CFD, added vent arrays (φ0.3mm, pitch 1.2mm)
（3）Reliability Assurance
- 100% X-ray + 5D AOI for BGA inspection
- CAF-resistant material (Tg≥170°C), passed 1000 thermal cycles (-40°C~125°C)
3. Results & Benefits
| Metric | Before | KKPCB Solution | Improvement |
|---|---|---|---|
| PCB Size | 100×80mm | 80×60mm | 23% smaller |
| MOSFET ΔT | 32°C @20A | <15°C @20A | 53% lower |
| PWM Crosstalk | -25dB | <-40dB | 60% better isolation |
| Yield Rate | 92% | 99.1% | 7.5% cost savings |
▸ Achieved IEC 61000-6-4/CE certification, accelerated time-to-market by 4 months
▸ Became the customer’s exclusive PCB supplier in APAC, with monthly orders exceeding 15Kpcs
4. KKPCB Core Capabilities
✅ Any-Layer HDI: Supports 16L + 0.05mm microvias
✅ Hybrid Thermal Solutions: Custom Cu/Al/graphene substrates
✅ Industrial-Grade Reliability: Certified to IPC-6012 Class 3
► Is This Right for Your Project?
For high-density, high-power PCBA in robotics/industrial automation, contact KKPCB for a free design review:
📧 Email: [email protected]
🌐 Website: https://www.kkpcb.net/
