Special Shape Hexagon LED Aluminum Substrate PCB Board is a custom-cut metal core circuit board manufactured on an aluminum base for high-power LED lighting. The hexagonal outline is die-cut or routed to match modular honeycomb LED fixture designs, providing efficient heat dissipation, stable electrical insulation and clean visual appearance for decorative and architectural lighting projects.
1. Specifications
- Board Type: Aluminum Metal Core PCB (MCPCB), custom special shape
- Outline Shape: Hexagonal (6-sided), custom polygon / irregular shape available on request
- Base Material: Aluminum alloy 1060 / 5052, rigid metal base
- Dielectric Layer: Thermally conductive insulation layer, 75μm – 150μm
- Copper Foil: 1oz (35μm) / 2oz (70μm) / 3oz (105μm)
- Board Thickness: 1.0mm / 1.5mm / 2.0mm
- Thermal Conductivity: 1.0 W/m·K / 1.5 W/m·K / 2.0 W/m·K / 3.0 W/m·K optional
- Solder Mask: White / Green / Black LPI solder mask, UL94 V-0
- Surface Finish: HASL-LF / ENIG / OSP
- Minimum Trace / Space: 0.15mm / 0.20mm
- Outline Tolerance: ±0.1mm
- Mounting Holes: Custom position and diameter per customer drawing
- Breakdown Voltage: ≥2500V AC
- Insulation Resistance: ≥1000 MΩ
- Maximum Operating Temperature: 130°C
- Certification: UL, RoHS 2.0, REACH
- Quality Test: 100% open/short electrical test, insulation resistance verification, visual outline inspection
2. Core Features
- Custom hexagonal outline: precision-cut 6-sided shape designed for honeycomb modular LED arrangements, each board fits together to form large continuous lighting panels
- High heat dissipation: aluminum base conducts heat directly from LED chips to the external heatsink, lowering junction temperature and extending LED lifespan
- White solder mask option: high light reflectivity (>90%) boosts LED light output efficiency for decorative and architectural lighting
- Strong mechanical rigidity: aluminum substrate resists warping, bending and vibration under long-term outdoor operation
- Reliable insulation: thermally conductive dielectric layer isolates copper traces from the aluminum base, preventing electrical short circuits
- Clean edge finish: routed or die-cut hexagon edges are smooth, free of burrs, suitable for visible modular assembly
- Flexible layout design: LED pads, wiring traces and mounting holes are arranged according to customer lighting geometry
- Good weather stability: low water absorption and stable thermal performance for outdoor and humid environments
3. Manufacturing & Process Advantages
- Custom shape machining: CNC routing produces accurate hexagonal outline with consistent dimensions batch after batch; special die cutting available for large volume orders
- Controlled dielectric thickness: thermal conductivity performance remains consistent across every production lot
- Thick copper option: up to 3oz copper foil supports high-current LED driver circuits
- Anti-yellowing solder mask: white and colored masks maintain appearance under long-term heat and UV exposure
- Precision pad opening: solder mask windows align accurately to LED pads, no mask residue affecting soldering quality
- Full insulation testing: 100% dielectric resistance check before shipment eliminates leakage risk
- Panel optimization: multiple hexagonal boards are nested efficiently on production panels to reduce material waste and unit cost
- DFM review: engineering team checks trace layout, mounting hole position and edge clearance before manufacturing
- Fast prototype turnaround: special shape MCPCB samples available in short lead time for lighting fixture development
- Prototype and mass production both supported, with consistent outline and thermal performance between sample and volume orders
4. Typical Applications
- Honeycomb modular LED panel lights and decorative ceiling lighting
- Hexagonal LED wall panels, gaming room wall lights and studio lighting grids
- Architectural accent lighting and commercial building facade decorative LED boards
- High-power LED flood lights, spotlight modules and track lighting assemblies
- Stage and event decorative LED lighting arrays
- Outdoor landscape lighting modules and garden LED fixtures
- LED display backlight units with custom polygon layout
- Automotive decorative interior LED modules
- Custom-shaped power electronics boards requiring aluminum heat dissipation base
5. About Us
We are a professional PCB manufacturer based in China, specializing in OEM/ODM custom printed circuit board production for global customers. With years of manufacturing experience, we provide one-stop PCB solutions covering standard FR-4 rigid boards, aluminum MCPCBs, HDI boards, high-frequency boards, ceramic substrates, rigid-flex boards and FPC flexible circuits.
Our factory is equipped with advanced production lines and testing facilities, ensuring reliable quality from prototype to mass production. We strictly follow IPC standards and hold UL, RoHS and REACH certifications. Our engineering team provides DFM feedback, technical support and fast response to customer inquiries.
We serve customers across Europe, North America, Russia, Southeast Asia and other regions, delivering stable quality, competitive pricing and on-time delivery. Whether you need a small batch prototype, custom-shaped LED aluminum board or high-volume production order, we are ready to support your project.
For inquiries, please send your Gerber files, mechanical drawings and thermal requirements to our sales team for an engineering review and quick quotation within 24 hours.
