Inquire: Call 0086-755-23203480, or reach out via the form below/your sales contact to discuss our design, manufacturing, and assembly capabilities.
Quote: Email your PCB files to Sales@pcbsync.com (Preferred for large files) or submit online. We will contact you promptly. Please ensure your email is correct.
Notes: For PCB fabrication, we require PCB design file in Gerber RS-274X format (most preferred), *.PCB/DDB (Protel, inform your program version) format or *.BRD (Eagle) format. For PCB assembly, we require PCB design file in above mentioned format, drilling file and BOM. Click to download BOM template To avoid file missing, please include all files into one folder and compress it into .zip or .rar format.
How to Order Bergquist MCPCB Prototypes: Quick Turn Guide
Ordering a Bergquist MCPCB prototype is not the same as submitting an FR-4 board to an online instant-quote service. The thermal and electrical properties that make Bergquist Thermal Clad worth specifying in the first place — the dielectric grade’s verified breakdown voltage, thermal conductivity, and Tg — are also the properties that require a more deliberate ordering process. Submit a vague spec and you will receive either a generic MCPCB with unrelated dielectric, a delay while the fabricator seeks clarification, or a quote that looks attractively low because the fabricator substituted a cheaper material.
This guide covers the complete process for ordering a Bergquist MCPCB prototype efficiently: what to specify in the RFQ, how to prepare your design files, what the realistic quick-turn lead time looks like, and what to verify when the boards arrive. For background on Bergquist Thermal Clad dielectric grades, their specifications, and application selection, the Bergquist PCB reference page is the right starting point before you reach the ordering stage.
Understanding What “Quick Turn” Means for Bergquist MCPCB Prototype Orders
Quick-turn lead times for FR-4 prototype boards — 24 to 48 hours from some online services — are possible because those fabricators maintain large stocks of standard FR-4 laminate in common configurations, and the processing steps are entirely standard. Bergquist MCPCB prototype lead times are longer for two structural reasons.
First, TCLAD Thermal Clad laminate (the current manufacturer of what was historically the Bergquist product line, operating from Prescott, Wisconsin) is a specialty material. Fabricators that stock it hold it in the most common grade-copper-base combinations: typically HT-07006, HT-04503, and MP-06503 at 1 oz copper on 1.5 mm aluminium 5052. HPL-03015, HT-09009, and CML-11006 are less commonly held in stock and may require a material procurement cycle before fabrication begins.
Second, the fabrication process itself adds steps that FR-4 does not require: diamond-tooling drill and routing operations on the aluminium substrate, controlled lamination press cycles, dielectric void inspection, and ENIG surface finish processing. Each of these adds time to the fabrication cycle.
Table 1: Realistic Bergquist MCPCB Prototype Lead Times by Service Level
Service Level
Typical Lead Time
Conditions
Cost Premium
Standard prototype
10–15 business days
Most grades, standard spec
Baseline
Quick turn
5–7 business days
Common grades in stock, simple design
25–40% over standard
Expedited quick turn
3–5 business days
HT-04503, HT-07006, MP at 1 oz / Al 5052
50–70% over standard
Rush (best-effort)
2–3 business days
Very simple boards, stocked grade only
80–120% over standard
HPL-03015 or HT-09009
12–20 business days
Material procurement may be needed
Standard + material lead
For most engineering teams, the 5–7 business day quick-turn tier is the practical target for a first Bergquist MCPCB prototype — fast enough to keep a development schedule moving, achievable with common stocked grades, and without the extreme cost premium of same-week rush service.
Step 1: Select Your Bergquist Grade Before You Write the RFQ
The single most common delay in Bergquist MCPCB prototype ordering is grade selection that happens after RFQ submission rather than before. Fabricators that receive a spec saying “Bergquist HT grade, 2.2 W/m·K” without a specific grade designator have to come back and ask — and that back-and-forth adds a day or more to the process.
Choose your grade before contacting any fabricator. The decision is driven by three parameters in priority order: voltage isolation requirement, maximum continuous operating temperature, and thermal resistance budget. Use the table below as a quick reference.
For the first prototype of most LED and low-voltage power electronics designs, HT-04503 is the most practical starting point: it combines 2.2 W/m·K thermal performance, 11 kVAC breakdown, and 150 °C UL RTI in the most widely stocked dielectric thickness (4.5 mil / 114 µm). It is available from qualified fabricators without material lead time in most cases, and its properties are adequate for the majority of single-layer MCPCB applications outside extreme high-voltage or highest-possible thermal conductivity requirements.
Step 2: Prepare Your Design Files — MCPCB-Specific Requirements
Gerber files for a Bergquist MCPCB prototype follow the same RS-274X format standard as FR-4 boards, but several MCPCB-specific items in the fabrication drawing and notes are critical and frequently omitted on first submissions.
What Every Bergquist MCPCB Prototype Package Needs
The complete file package should include Gerber files for copper layer(s), solder mask, silkscreen, and board outline; a drill file in Excellon format; a fabrication drawing (PDF or DXF) with dimensions and tolerances; and a specification notes section that explicitly covers all of the following items.
Board outline and substrate thickness. State finished board thickness (dielectric + aluminium base, not just nominal) and call out any mounting holes, slots, or non-rectangular cutouts with dimensional tolerances. Aluminium MCPCB routing requires diamond-coated tooling and slower feed rates than FR-4 — complex profiles add cost and time, so simple rectangular outlines prototype faster and cheaper.
Bergquist grade by exact designation. Write “Bergquist Thermal Clad HT-07006 (TCLAD-manufactured), aluminium alloy 5052-H34 base, 1.5 mm substrate” — not “Bergquist HT grade” or “2.2 W/m·K aluminium PCB.” The specific grade and TCLAD as the laminate source should be named. Include a note: “TCLAD Certificate of Conformance with lot numbers required at delivery.”
Copper weight. State copper weight explicitly: “1 oz (35 µm) finished copper, circuit layer top.” If using 2 oz, note it and confirm with the fabricator that their solder mask process handles thick-copper step height.
Surface finish. Specify ENIG: “ENIG per IPC-4552, Ni 3–5 µm, Au 0.05–0.1 µm.” HASL is not recommended on thin-dielectric Bergquist grades due to disbonding risk. State this explicitly if you want to prevent a fabricator from defaulting to HASL to speed turnaround.
Via and hole notes. For single-layer SMD-only boards: “No plated through holes required.” For boards with mounting holes: “Non-plated mounting holes, 3.2 mm diameter, standard countersink as shown.” If any vias penetrate the aluminium substrate, add: “Via isolation required — resin fill and re-drill process, specify in DFM response.” Do not assume the fabricator will apply via isolation without being told.
Hipot test requirement. Add a test note: “100% hipot test required, 3 kVAC minimum between copper circuit layer and aluminium substrate per IPC-6012.” This is standard on production boards and should be confirmed for prototype lots as well.
IPC Class. State Class 2 or Class 3. For automotive, medical, or certification-bound designs, Class 3 should be explicitly called out.
Step 3: Writing the RFQ That Gets You a Useful Quote
The RFQ for a Bergquist MCPCB prototype is not just a file submission — it is the document that determines whether the fabricator quotes the board you actually designed or a commodity substitute that looks the same in a spreadsheet.
A complete Bergquist MCPCB prototype RFQ includes the design file package above plus the following written specification:
Quantity required (prototype quantity, typically 5–10 boards), requested lead time and service tier (standard or quick-turn), required delivery date, fabrication standard (IPC-6012 Class 2 or 3), material certificate requirement (TCLAD lot CoC at delivery), and any special packaging or labelling requirements. If the design will go into automotive production eventually, note IATF 16949 certification requirement even at prototype stage — this narrows the supplier pool but ensures you are qualifying the right fabricator from the first run.
Send the complete RFQ to at least two qualified fabricators and compare not just price but response quality. A fabricator that responds with a comprehensive quote addressing every line item, confirms material stock availability for the specific grade, and asks technically relevant clarifying questions is demonstrating the process engagement that translates into correct boards. A fabricator that responds with a price in 20 minutes without addressing the grade or CoC requirement is telling you how they will treat the specification on the shop floor.
Step 4: Evaluating the DFM Response
Most qualified Bergquist MCPCB fabricators perform a DFM (Design for Manufacturability) review before starting production. For prototype orders, this review typically takes 4–24 hours and identifies any issues that would cause fabrication problems or require design changes.
Common DFM flags on first-time MCPCB designs include copper-to-board-edge clearance violations (aluminium routing creates burrs that can short copper at the board edge if the clearance is less than 0.5 mm), solder mask aperture issues over copper pads without adequate mask dam, annular ring size insufficient for the drill-to-pad ratio after accounting for the aluminium layer drilling offset, and thermal pad designs that do not match the fabricator’s ENIG aperture opening capability.
Respond to DFM feedback promptly and in writing. DFM response time is one of the largest variables in quick-turn lead time — a fabricator waiting on your DFM approval is not building your board. Clear the DFM hold as soon as possible, confirm any design modifications, and get explicit written confirmation that the approved DFM files are in production.
Step 5: What to Verify When Boards Arrive
Prototype receipt is not the end of the Bergquist MCPCB prototype process — it is the start of incoming verification. For first-article prototypes, the following checks protect you from discovering material or process problems during assembly rather than at goods-in.
The CoC review takes five minutes and requires no equipment. The XRF plating check requires an XRF instrument or a third-party measurement service — many contract assemblers have one on site. The hipot check requires a basic hipot tester (under $500) and takes two minutes per board. The thermal resistance spot-check requires a small through-hole resistor, two thermocouples, a bench power supply, and a multimeter, and takes about 20 minutes for the first board. Together, these six checks give you meaningful confidence that the boards you received match the specification you ordered before you commit to assembling a prototype that will go into thermal and electrical testing.
Common Mistakes Engineers Make on First Bergquist MCPCB Prototype Orders
Not specifying the grade explicitly. “Bergquist HT” is not a grade designation. HT-04503 and HT-09009 are both HT series, but their dielectric thickness, breakdown voltage, and thermal resistance differ by factors of 2–4×. Always use the full grade designation.
Forgetting to require a TCLAD CoC. The CoC requirement must appear in the fabrication notes of the order, not just in an email. Fabricators working from the Gerber package and spec notes will not automatically include it unless it is written into the document set.
Specifying HASL to save time or cost. HASL is not recommended for Bergquist Thermal Clad, particularly on thin dielectric grades like HPL-03015. The thermal shock of HASL application increases disbonding risk. The 20–30% price premium for ENIG is small relative to the cost of a disbonded board discovered at assembly.
Missing the via isolation note. If any via, mounting hole, or drill penetrates the aluminium substrate, via isolation (resin fill, cure, re-drill) is required to prevent a short to the baseplate. Single-layer SMD-only boards with non-plated mounting holes do not need this, but it must be explicitly stated either way.
Treating the prototype as a production-equivalent qualification. A 5-piece prototype from a fabricator that is not your production source qualifies the design but not the supply chain. When you identify your production fabricator, run a separate first-article inspection on their process even if the design has already been validated.
Useful Resources for Ordering Bergquist MCPCB Prototypes
Resource
Description
Link
TCLAD Inc.
Current manufacturer of authentic Thermal Clad laminate; contact for local distribution
Q1: Can I order a single Bergquist MCPCB prototype, or is there a minimum quantity?
Many qualified fabricators accept single-piece orders for MCPCB prototypes. The unit economics are unfavourable at quantities below 5 — setup and engineering costs are amortised over very few boards, so the per-unit price is high — but the option exists. For a first thermal validation prototype where you only need one board to confirm junction temperature performance, ordering a single piece is reasonable. For electrical and mechanical validation where you anticipate needing backup boards or destructive testing, ordering 3–5 pieces is more practical. The per-unit cost at 5 pieces compared to 1 piece is typically 30–50% lower as setup costs are spread more effectively.
Q2: How do I confirm a fabricator is using authentic TCLAD laminate and not a generic substitute?
Require the TCLAD Certificate of Conformance with lot numbers as a delivery condition, stated in your fabrication notes, before the order is placed. When the boards arrive, verify that the lot numbers on the CoC are consistent with genuine TCLAD supply chain documentation. If you have a TCLAD distributor contact (Digikey, Mouser, or Arrow all distribute TCLAD), your distributor can confirm whether the lot numbers correspond to genuine TCLAD production. For a quick physical check, run a hipot test at the full dielectric breakdown voltage of the specified grade — genuine HT-07006 will hold 11 kVAC with significant margin; many generic 2.2 W/m·K dielectrics at 6 mil thickness will not.
Q3: My board design uses mounting holes through the aluminium substrate. Does this complicate the prototype order?
Non-plated mounting holes through the aluminium substrate are standard and add no special process complexity beyond diamond-tooling the holes to the correct diameter. State them clearly in the fabrication drawing with dimensional tolerance and specify “non-plated” explicitly. What does add complexity is plated through holes that must carry current between circuit layers and penetrate the metal — those require the via isolation process (resin fill, cure, re-drill) to prevent a short to the baseplate. If your design has no such vias, standard non-plated holes through the aluminium are not a quick-turn obstacle and most qualified fabricators handle them as standard.
Q4: My application is automotive and the prototype eventually needs IATF 16949 supply chain. Should I order the prototype from my planned production fabricator?
Ideally, yes. The qualification effort of auditing a fabricator, reviewing their material CoC process, and running a first-article inspection is most efficiently done once against the production supplier rather than twice against a prototype shop and then the production shop separately. If your planned production fabricator also offers quick-turn prototype service — and many IATF 16949 qualified MCPCB houses do — ordering prototypes there simultaneously qualifies the supply chain and validates the design. The prototype may cost slightly more than from a pure-prototype shop, but the dual qualification value justifies it for automotive development programmes where schedule compression is typical.
Q5: What is the most common reason a Bergquist MCPCB prototype order gets delayed?
By a significant margin, the most common cause of delay is DFM hold — the fabricator’s engineering team identifies a problem in the design files and puts the order on hold pending resolution. The most frequent DFM issues on first-time MCPCB designs are: copper-to-edge clearance violation (copper trace too close to the routed board edge, where the aluminium burring from routing can cause a short), missing or inconsistent board outline layer in the Gerber package, and missing via isolation specification on boards with through-hole drills. A thorough pre-submission DFM check using your CAD tool’s built-in rule checker, cross-referenced against the fabricator’s published MCPCB design rules, eliminates most of these hold causes before submission and recovers a day or more of lead time on every prototype cycle.
Summary: The Quick-Turn Bergquist MCPCB Prototype Order in Practice
A well-executed Bergquist MCPCB prototype order follows a straightforward sequence: select the grade before writing the RFQ, prepare a complete file package with all MCPCB-specific notes, write a specification that locks down grade designation and TCLAD CoC requirement, resolve DFM feedback promptly, and verify the received boards against the six-point incoming check before committing to assembly.
The 5–7 business day quick-turn tier is achievable for common grades (HT-04503, HT-07006, MP-06503 at standard copper and base configurations) from fabricators that genuinely stock TCLAD laminate. Longer lead times typically trace to one of three causes: an uncommon grade requiring material procurement, DFM hold caused by incomplete or ambiguous fabrication notes, or a fabricator that does not actually stock the material they quoted against.
The extra specification effort at the ordering stage — 30 minutes writing clear fabrication notes compared to a vague Gerber submission — prevents the most common delay, the most common material substitution risk, and the most common incoming inspection failure. It is the highest-ROI engineering activity in the Bergquist MCPCB prototype process.
For Bergquist Thermal Clad grade specifications, dielectric properties, and application selection guidance, visit the Bergquist PCB reference page.
Inquire: Call 0086-755-23203480, or reach out via the form below/your sales contact to discuss our design, manufacturing, and assembly capabilities.
Quote: Email your PCB files to Sales@pcbsync.com (Preferred for large files) or submit online. We will contact you promptly. Please ensure your email is correct.
Notes: For PCB fabrication, we require PCB design file in Gerber RS-274X format (most preferred), *.PCB/DDB (Protel, inform your program version) format or *.BRD (Eagle) format. For PCB assembly, we require PCB design file in above mentioned format, drilling file and BOM. Click to download BOM template To avoid file missing, please include all files into one folder and compress it into .zip or .rar format.
