Technology šŸ“… December 2, 2024 ā± 5 min read

The Future of HDI PCB Manufacturing

← Back to Blog

High-Density Interconnect (HDI) PCBs represent a significant leap forward in circuit board technology, enabling miniaturization and enhanced performance. As devices continue to shrink while functionality expands, HDI technology becomes essential for everything from smartphones to medical implants.

What Makes HDI Different?

  • Microvias: Laser-drilled holes typically less than 150 micrometers in diameter
  • Fine line traces: Trace widths and spacing of 75 micrometers or less
  • High layer counts: Often 8+ layers with sequential lamination cycles
  • Advanced materials: Low-loss laminates for improved signal integrity

Key Applications Driving HDI Adoption

Consumer Electronics

Smartphones, tablets, and wearables rely heavily on HDI to pack functionality into minimal space. Modern devices feature 20+ layer HDI boards with dense microvia structures.

Medical Devices

Pacemakers, insulin pumps, and imaging devices all leverage HDI technology for compact, reliable performance.

Aerospace & Defense

Mission-critical systems demand the reliability HDI provides — including avionics, satellite communications, and guidance systems.

Manufacturing Challenges & Solutions

Laser Drilling

COā‚‚ and UV lasers precisely create microvias with minimal thermal damage to surrounding materials. Our facility uses state-of-the-art systems capable of 50µm-diameter vias.

Sequential Lamination

HDI designs often require multiple lamination cycles, each adding complexity. Engineers optimize registration to maintain 25µm alignment tolerances.

Copper Plating & Filling

Microvia plating requires specialized chemistry to ensure reliability and mitigate voids.

Future Trends

  • Any-layer HDI: All layers interconnected through microvias
  • Embedded components in substrate
  • Substrate-like PCBs (SLPs) approaching semiconductor packaging density
  • 5G & mmWave: New material requirements above 30GHz

Partner with Xekera for Your HDI Needs

Our engineering team brings decades of HDI experience to your project — from initial design review through final testing.

Have a Project in Mind?

Contact our team to discuss your PCB manufacturing needs and get a custom quote.

Request a Quote