High Frequency PCB

Design Support & Cost Optimization for High-Frequency PCBs

Designing PCBs for RF, microwave, and mmWave applications requires more than standard layout practices. At Highleap Electronics, our engineering team works closely with customers to optimize signal integrity, impedance control, and manufacturability right from the design stage. We help you avoid common pitfalls like excessive vias, long signal loops, and improper trace routing—ensuring your layout supports clean signal transmission even at GHz frequencies.

To support reliable high-frequency performance, we follow proven layout guidelines: minimizing crosstalk between signal lines, using 45° trace bends instead of sharp corners, and reducing the use of lossy soldermask on critical signal paths. We also advise on material choices that reduce dielectric loss and surface roughness issues caused by skin effect at high frequencies. Whether it’s antenna design or radar circuitry, our insights help customers avoid EMI issues and achieve better signal-to-noise performance.

Highleap also provides cost-effective hybrid stack-up solutions, combining premium RF cores like Rogers or Taconic with FR-4 for non-critical layers. This balances performance with budget control. From stack-up planning to DFM checks and impedance matching support, we’re here to guide you through every step—accelerating your design cycle while reducing iteration costs.

Materials for High-Frequency PCB Fabrication

Material selection is at the core of high-frequency PCB performance. At Highleap Electronics, we maintain a well-managed inventory of high-frequency laminates to support fast prototyping and stable mass production. Our factory works closely with globally recognized suppliers to ensure material authenticity, consistent dielectric performance, and reliable sourcing.

Extensive In-House Inventory of HF Materials

We stock a wide range of high-performance RF and microwave materials, including:

• • Rogers: RO4003C, RO4350B, RO3003, RO3010, RT/duroid 5870, 5880, 6002, 6010LM
  • Taconic: RF-35, TLY-5, TLX-8, TSM-DS3, CER-10
  • Isola: IS620, I-Tera MT40, Astra MT77
  • Panasonic: Megtron 6, Megtron 7 (for hybrid RF + digital systems)
  • Nelco: N4000-13EPSI, N9000 series
  • Arlon: 85N, AD255C
  • Other specialty substrates: PTFE, LCP, PPO, and ceramic-filled materials for millimeter-wave and radar-grade applications

These materials cover a broad range of dielectric constants (Dk), dissipation factors (Df), and thermal coefficients, allowing us to tailor the performance of your design across 1GHz to 77GHz+ frequencies.

Support for Hybrid Stack-Ups and Mixed Lamination

We offer full support for hybrid PCB construction, combining high-frequency materials with standard FR4 or low-loss core/prepreg systems to balance performance, cost, and manufacturability. Our experienced CAM and process engineers can optimize your layer stack-up to ensure:

• • Stable impedance control across transmission lines
  • Low insertion loss at high frequencies
  • Minimal dielectric skew in differential pairs
  • Compatibility with specific copper weights and surface finishes

Flexible Material Procurement and Customer-Supplied Materials

In addition to our long-term stocked materials, we also support:

• • Rapid procurement of customer-specified laminates (including rare or custom-coded materials) via trusted distributors
  • Customer-supplied material processing (consignment) with full handling compliance
  • Material substitution suggestions based on electrical, mechanical, and thermal equivalence for cost or lead time optimization

Our sourcing team works closely with Rogers, Taconic, and regional agents to ensure fast material lead times and secure original manufacturer supply channels, especially for PTFE-based and high-Dk materials with long procurement cycles.

High-Frequency PCB Manufacturing Capabilities

Highleap Electronics delivers a comprehensive range of fabrication capabilities tailored to high-frequency applications, from RF to mmWave. We combine precision manufacturing with tight process control to meet the stringent requirements of today’s high-speed, high-density RF systems.

Our capabilities include:

• Multilayer RF PCB fabrication (up to 60 layers and more)
• Hybrid stack-up construction (PTFE + FR4, Megtron + Isola, etc.)
• Controlled impedance routing (±5% tolerance)
• Fine-line etching (trace/space down to 2/2 mil or 50μm)
• Back drilling and via-in-pad for signal integrity
• Plated cavity and edge plating for shielding and antenna housing
• Microwave structures such as filters, couplers, and antennas
• Tight dielectric thickness control for consistent electrical length
• Low-loss surface finishes: ENIG, ENEPIG, immersion silver, soft gold

We support custom stack-ups, embedded passive structures, and antenna-in-substrate designs for applications including radar sensors, satellite communications, IoT, and wireless base stations.

One-Stop Assembly Services for High-Frequency PCBs

Highleap provides full turnkey and partial turnkey PCB assembly services tailored for RF, microwave, and mmWave systems.

Assembly Capabilities:

• SMT & through-hole assembly for RF modules

• High-precision placement of sensitive RF components

• Handling of RF connectors (SMA, SMP, U.FL)

• Shielding cans, cavity placement, and heat sink integration

• BGA and fine-pitch component inspection via X-ray

• Low-residue flux processes for dielectric cleanliness

• BOM sourcing support and cost optimization

Quality Assurance for High-Frequency PCBs and Assemblies

At Highleap Electronics, quality is at the core of everything we do. For high-frequency PCBs and assembled RF modules, we implement specialized inspection and testing protocols to ensure reliability, signal performance, and compliance with industry standards.

PCB Fabrication Quality Control

• 100% Electrical Testing to detect shorts and opens
• Impedance Coupon Validation for controlled-impedance traces
• Automated Optical Inspection (AOI) for fine-line verification
• X-ray Inspection of multilayer alignment and via structures
• Cross-Section Analysis to verify plating thickness, hole wall quality, and layer registration
• Optional TDR, S-Parameter, and Insertion Loss Testing for critical signal paths
• Compliance with IPC-6018 (High-Frequency PCBs) and Class 2 / Class 3 reliability standards

PCBA (Assembly) Quality Control

• AOI and X-ray Inspection for BGAs, fine-pitch ICs, and passive components
• Solder Paste Inspection (SPI) for print quality and volume control
• In-Circuit Testing (ICT) and Functional Testing upon request
• Strict ESD and humidity control for RF-sensitive components
• Use of low-residue or no-clean flux to minimize dielectric impact
• Careful handling of RF connectors (SMA, SMP, U.FL) to preserve performance
• RoHS and REACH compliance for global market access

Our experienced QA team ensures every board and assembly meets your design’s exact specifications and performs reliably in mission-critical environments.