How much voltage can a PCB handle?

Understanding High Voltage PCBs

A high voltage PCB is a printed circuit board designed to withstand and operate at higher voltage levels compared to standard PCBs. The definition of “high voltage” can vary depending on the industry and application, but typically, PCBs operating at voltages above 50V are considered high voltage.

Factors Affecting Voltage Handling Capacity

Several factors influence a PCB’s ability to handle high voltages:

  1. Dielectric strength: The dielectric strength of the PCB material determines its ability to withstand high voltages without breaking down or allowing current to flow through the insulating material.

  2. Creepage and clearance distances: Creepage is the shortest distance between two conductive parts along the surface of the insulating material, while clearance is the shortest distance through air. Maintaining sufficient creepage and clearance distances prevents arcing and flashover.

  3. Copper thickness: Thicker copper traces can handle higher currents and voltages, reducing the risk of overheating and damage to the PCB.

  4. Insulation materials: The choice of insulation materials, such as soldermask and conformal coatings, can enhance the PCB’s ability to withstand high voltages and prevent surface contamination.

Designing High Voltage PCBs

When designing a high voltage PCB, several key considerations must be taken into account to ensure the board’s reliability and safety.

Material Selection

Choosing the right PCB material is critical for high voltage applications. The most common materials used for high voltage PCBs are:

  1. FR-4: A flame-retardant, glass-reinforced epoxy laminate with good mechanical and electrical properties. FR-4 is suitable for voltages up to 500V.

  2. Polyimide: A high-temperature, flexible material with excellent electrical properties and resistance to chemicals and moisture. Polyimide PCBs can handle voltages up to 1000V.

  3. Ceramic: Ceramic substrates, such as alumina and beryllia, offer excellent thermal conductivity and high dielectric strength, making them suitable for voltages above 1000V.

Creepage and Clearance

Maintaining adequate creepage and clearance distances is essential for preventing arcing and flashover in high voltage PCBs. The required distances depend on factors such as the voltage level, pollution degree, and material group.

Voltage (V) Creepage Distance (mm) Clearance Distance (mm)
50-100 0.6 0.2
100-150 0.8 0.5
150-300 1.5 1.5
300-600 3.0 3.0
600-1000 5.5 5.5

Trace Sizing and Spacing

When designing high voltage PCBs, it is essential to use wider traces and greater spacing between traces to minimize the risk of arcing and improve heat dissipation. The following table provides general guidelines for trace width and spacing based on voltage levels:

Voltage (V) Minimum Trace Width (mm) Minimum Trace Spacing (mm)
50-100 0.3 0.6
100-150 0.4 0.8
150-300 0.6 1.5
300-600 1.0 3.0
600-1000 1.5 5.5

Component Selection

Selecting components rated for high voltage operation is crucial for ensuring the reliability and safety of the PCB. When choosing components, consider factors such as:

  1. Voltage rating
  2. Power dissipation
  3. Insulation materials
  4. Package type (e.g., through-hole or surface-mount)

Manufacturing and Testing High Voltage PCBs

Manufacturing and testing high voltage PCBs require specialized processes and equipment to ensure the boards meet the necessary performance and safety requirements.

Manufacturing Processes

  1. Multilayer construction: High voltage PCBs often utilize multilayer construction to increase creepage and clearance distances and improve insulation between layers.

  2. Controlled impedance: Maintaining controlled impedance is essential for high voltage PCBs to minimize signal distortion and ensure proper operation.

  3. Plated through-holes: Plated through-holes provide reliable electrical connections between layers and improve the mechanical strength of the board.

  4. Surface finishes: Choosing the appropriate surface finish, such as HASL, ENIG, or OSP, can enhance the PCB’s ability to withstand high voltages and prevent corrosion.

Testing and Certification

High voltage PCBs must undergo rigorous testing and certification to ensure they meet the required safety and performance standards. Some common tests include:

  1. Dielectric withstand test: Applies a high voltage between conductors to verify the insulation’s ability to withstand the stress without breakdown.

  2. Insulation resistance test: Measures the resistance between conductors to ensure adequate insulation and prevent leakage currents.

  3. Partial discharge test: Detects the presence of partial discharge activity, which can lead to insulation degradation and eventual failure.

  4. Clearance and creepage measurement: Verifies that the PCB maintains the required clearance and creepage distances as per the applicable standards.

High voltage PCBs may also require certification to industry-specific standards, such as UL, IEC, or EN, depending on the application and target market.

Frequently Asked Questions (FAQ)

  1. What is considered a high voltage for PCBs?
    A: PCBs operating at voltages above 50V are generally considered high voltage, although the exact definition may vary depending on the industry and application.

  2. Can FR-4 be used for high voltage PCBs?
    A: FR-4 is suitable for high voltage PCBs operating at voltages up to 500V. For higher voltages, materials like polyimide or ceramic may be more appropriate.

  3. Why are creepage and clearance distances important in high voltage PCB design?
    A: Maintaining sufficient creepage and clearance distances prevents arcing and flashover, which can lead to insulation breakdown and PCB failure.

  4. What are some common applications for high voltage PCBs?
    A: High voltage PCBs are used in various applications, such as power supplies, automotive electronics, medical devices, aerospace systems, and industrial control equipment.

  5. How can I ensure my high voltage PCB meets the necessary safety standards?
    A: To ensure your high voltage PCB meets the required safety standards, follow best practices for design, manufacturing, and testing, and seek certification from the relevant industry-specific standards organizations, such as UL, IEC, or EN.


Designing, manufacturing, and testing high voltage PCBs require careful consideration of factors such as material selection, creepage and clearance distances, trace sizing and spacing, and component selection. By understanding the limitations and capabilities of PCBs in high voltage applications and following best practices for design and manufacturing, engineers can create safe, reliable, and high-performance boards for a wide range of industries and applications.