PTFE PCB Manufacturer

A PTFE PCB (also called Teflon PCB) is a printed circuit board manufactured using polytetrafluoroethylene-based laminates. PTFE materials offer the lowest dielectric loss among common PCB substrates, with dissipation factor (Df) as low as 0.0009. This makes PTFE PCBs the preferred choice for aerospace electronics, radar systems, satellite communication, and mmWave applications where signal loss must be minimized. PTFE PCBs require specialized manufacturing processes compared to standard FR4 or hydrocarbon-based Rogers materials.

Rogers is a brand that makes both PTFE-based and non-PTFE laminates. Rogers RT/duroid series (RT5880, RT5870) are PTFE-based materials. Rogers RO4000 series (RO4350B, RO4003C) are hydrocarbon-based and process more like standard FR4. PTFE PCB generally refers to boards using PTFE-based laminates from any manufacturer — including Rogers RT/duroid, Taconic TLY series, or F4B. The key advantage of PTFE over hydrocarbon Rogers is lower Df (0.0009 vs 0.0037), which means less signal loss at high frequencies. The trade-off is higher cost and more complex manufacturing.

PTFE is chemically inert with very low surface energy, which makes copper adhesion to hole walls extremely difficult using standard electroless copper processes. Without proper surface treatment, copper plating will not bond reliably to PTFE hole walls, leading to plating voids and reliability failures. We use plasma treatment before copper sinking on PTFE boards to activate the hole wall surface and ensure reliable copper bonding. This step is critical for multilayer PTFE PCB and is not performed by all manufacturers. PTFE also requires controlled lamination pressure and specialized drill parameters to avoid material deformation.

We support Rogers RT5880 (Dk 2.2, Df 0.0009), RT5870 (Dk 2.33, Df 0.0012), Taconic TLY-5A (Dk 2.17, Df 0.0009), TLY-5 (Dk 2.22), TLP-5 (Dk 2.2), RF-35 (Dk 3.5, Df 0.0018), RF-60A (Dk 6.5, Df 0.0038), CER-10 (Dk 10.0, Df 0.0035), and F4B series laminates. Material selection depends on working frequency, Dk requirement, loss budget and application environment.

Choose PTFE PCB when your application requires the lowest possible signal loss, typically for frequencies above 20GHz or in loss-critical designs such as radar receivers, satellite uplinks, aerospace RF modules, and mmWave circuits. RT5880 (Df 0.0009) has about 4x lower loss than RO4350B (Df 0.0037). For most 5G and general RF applications below 20GHz, RO4350B provides sufficient performance at lower cost and with simpler manufacturing. If your loss budget allows RO4350B, it is usually the more practical choice.

Yes. We support PTFE + FR4 hybrid stackups where RF-critical signal layers use PTFE laminates and structural or power layers use standard FR4. This approach significantly reduces material cost while maintaining low-loss performance on critical RF layers. Hybrid PTFE stackups require careful review of material compatibility, lamination sequence, and dielectric thickness. Engineering review is included before production for all hybrid stackup designs.

Please prepare: Gerber files (ZIP format), PTFE material requirement (e.g. Rogers RT5880 0.254mm), PCB stackup, board thickness, copper thickness, surface finish, quantity, impedance requirements, and working frequency. For hybrid stackups, please specify the material for each layer. Application details help us review material suitability and plasma process requirements before production.