FLEXXALUMINA®
Aluminum electronics beyond copper—from rigid PCBs to flexible circuits
FLEXXALUMINA® is an aluminum electronics platform for PCBs and flexible circuits.
Unlike conventional “aluminum PCBs” (metal core / IMS), FLEXXALUMINA® replaces copper as the electrical conductor. Aluminum is used as the current-carrying material in the circuit design—not merely as a mechanical or thermal substrate.
All FLEXXALUMINA® products are designed for SMT-compatible assembly, industrial reliability, and scalable high-volume production.
Overview
Product portfolio at a glance
From cost-efficient single-sided designs to advanced multilayer architectures—rigid, flexible, and thermally optimized.
Rigid FLEXXALUMINA® PCBs
Flexible printed circuits (FPCs)
IMS metal core PCBs (aluminum)
Direct Thermal Exchange (DTE) PCBs
Multilayer technology (pilot phase)
Indicative benchmark prices (LME reference)
Rigid electronics
Rigid FLEXXALUMINA® PCBs
Aluminum as a conductor material for industrial and automotive applications—from single-sided to multilayer.
High-volume production
Single-sided PCB
The technological foundation of the FLEXXALUMINA® platform. Optimized for high-volume and cost-sensitive applications.
Typical applications
- LED lighting modules
- Power supplies
- Industrial electronics
Key features
- Aluminum as a conductor material
- Copper-free solutions
- High cost efficiency
- Lower weight
High-volume production
Double-sided PCB
Higher wiring density and increased functional integration while maintaining the benefits of aluminum-based electronics.
Typical applications
- Automotive electronics
- Power electronics
- Industrial control systems
Technical features
- Aluminum conductors on both sides
- Vias where required
- Automotive-grade reliability
Pilot phase
Multilayer PCB
Advanced aluminum electronics architectures for complex, high-performance electronic systems.
Typical applications
- Battery management systems
- Automotive power modules
- Advanced industrial electronics
Availability: Available in pilot projects and co-development programs.
Indicative benchmark prices (LME reference)
Flexible electronics
Flexible printed circuits (FPCs)
Flexible aluminum-based circuits for lightweight, large-area, and distributed electronic systems.
High-volume production
Single-sided FPCs
Cost-efficient flexible circuits for sensor arrays, lighting systems, and large-area applications.
Typical applications
- Distributed voltage sensing and CCS architectures
- Battery interconnects
- Automotive interior and lighting systems
- IoT and sensor arrays
High-volume production
Double-sided FPCs
Higher wiring density for complex interconnect and distributed sensor applications.
Typical applications
- Distributed voltage sensing and CCS architectures
- Battery interconnects
- Automotive interior and lighting systems
- IoT and sensor arrays
Indicative benchmark prices (LME reference)
Conventional aluminum IMS solutions
Insulated Metal Sheet (IMS) PCBs
IMS PCBs offer significant advantages for thermally demanding applications.
This is where FLEXXALUMINA technology fully demonstrates its potential:
- No copper-aluminum bimetal build-up. This eliminates bow & twist issues typical of conventional IMS PCBs with copper conductors.
- Significantly improved mechanical stability during thermal cycling.
- Key distinction
- No copper-aluminum bimetal stack as the conductor system
- No bow & twist issues as commonly seen in Cu-Al IMS designs
- Improved mechanical stability during thermal cycling
For extreme thermal loads
Direct Thermal Exchange (DTE) PCBs
Direct Thermal Exchnage (DTE) PCBSs enable direct heat transfer from the component to the aluminum base, minimizing thermal interface resistance.
Ideal for:
- High-power LED modules
- Power electronics in automotive and industrial applications
Benefits:
- High heat dissipation performance
- Improved service life and reliability
- Reduced installation space by eliminating heat sinks or active cooling
Technology readiness level
Production & pilot technologies
High-volume production
- Single-sided PCBs
- Double-sided PCBs
- Single-sided FPCs
- Double-sided FPCs
- IMS aluminum PCBs
Pilot phase
- Multilayer FLEXXALUMINA® PCBs
- Advanced multilayer architectures
Contact us for pilot projects and co-development opportunities.
Selection guide
Which product is right for your application?
| Application | Recommended solution | Status |
|---|---|---|
| LED lighting | Single-sided PCBs | High-volume production |
| Power electronics | Double-sided PCBs | High-volume production |
| Large-area sensing | Single-sided FPCs | High-volume production |
| Distributed sensing | Double-sided FPCs | High-volume production |
| Cost-sensitive electronics | Single-sided PCBs | High-volume production |
| High-performance systems | Multilayer PCB / DTE PCB | Pilot phase |
Platform benefits
Shared features of all FLEXXALUMINA® products
Aluminum replaces copper as the conductor material
SMT-compatible assembly
Drop-in replacement for copper-based designs
Industrial reliability
Scalable high-volume production
Fully recyclable material concepts
Reduced material complexity through aluminum-based stacks
Next steps
For OEMs & product developers
Find solutions
Discuss the electrical and thermal requirements and implementation options with our engineering team.
For PCB manufacturers
Explore partnerships
Licensing model for manufacturing FLEXXALUMINA® PCBs and FPCs