What is HDI PCB?

Key Features of HDI PCBs

HDI PCBs offer several advantages over traditional PCBs due to their unique features:

  1. Finer Lines and Spaces: HDI PCBs use thinner copper traces and smaller spaces between them, allowing for higher wiring density. Typical line width and spacing in HDI PCBs range from 50 to 100 μm, compared to 100 to 150 μm in conventional PCBs.

  2. Smaller Vias: Vias in HDI PCBs are typically smaller than those in conventional PCBs. There are two main types of vias used in HDI PCBs:

  3. Microvias: These are blind or buried vias with a diameter of less than 150 μm, allowing for higher density interconnects between layers.
  4. Buried vias: These vias connect inner layers of the PCB without penetrating the outer layers, further increasing wiring density.

  5. Capture Pads: HDI PCBs use smaller capture pads for via connections, reducing the overall size of the board and allowing for more routing space.

  6. Multilayer Structures: HDI PCBs often have a higher number of layers compared to conventional PCBs, enabling more complex designs in a smaller space. They can have 8 or more layers, with some designs reaching up to 24 layers or more.

Benefits of HDI PCBs

The unique features of HDI PCBs offer several benefits for electronic devices:

  1. Miniaturization: The higher wiring density and smaller components in HDI PCBs allow for more compact designs, enabling the development of smaller and lighter electronic devices.

  2. Improved Performance: Shorter signal paths in HDI PCBs lead to improved electrical performance, reduced signal noise, and faster signal transmission, which is crucial for high-speed applications.

  3. Enhanced Functionality: The increased wiring density in HDI PCBs allows for more complex designs and the integration of more functions into a single board, leading to enhanced device functionality.

  4. Cost Reduction: Although the initial cost of HDI PCBs may be higher than conventional PCBs due to the advanced manufacturing processes involved, they can lead to overall cost savings by reducing the number of components and interconnections required.

Applications of HDI PCBs

HDI PCBs are widely used in various industries and applications that require high-performance, compact electronics:

  1. Consumer Electronics: Smartphones, tablets, wearables, and other portable devices heavily rely on HDI PCBs to achieve their compact sizes and advanced features.

  2. Telecommunications: Network equipment, routers, and switches use HDI PCBs to enable high-speed data transmission and processing.

  3. Aerospace and Defense: Avionics systems, satellites, and military equipment employ HDI PCBs for their reliability, performance, and space-saving properties.

  4. Medical Devices: Implantable devices, diagnostic equipment, and other medical electronics use HDI PCBs to achieve miniaturization and high functionality.

  5. Automotive Electronics: Advanced driver assistance systems (ADAS), infotainment systems, and other automotive electronics rely on HDI PCBs for their compact size and high performance.

Manufacturing Process of HDI PCBs

The manufacturing process of HDI PCBs involves several advanced techniques to achieve the high wiring density and small feature sizes:

  1. Laser Drilling: Microvias in HDI PCBs are typically drilled using laser technology, which allows for precise and small-diameter holes.

  2. Sequential Lamination: HDI PCBs are often built using a sequential lamination process, where layers are added one at a time, allowing for the creation of buried and blind vias.

  3. Copper Filling: After laser drilling, the microvias are filled with copper to create reliable interconnections between layers.

  4. Fine Line Patterning: Advanced photolithography and etching techniques are used to create the fine lines and spaces on the PCB.

  5. Surface Finish: HDI PCBs typically use a surface finish such as Immersion Gold (ENIG) or Electroless Nickel Electroless Palladium Immersion Gold (ENEPIG) to protect the exposed copper and improve solderability.

hdi pcb design Considerations

Designing HDI PCBs requires careful consideration of several factors to ensure optimal performance and manufacturability:

  1. Material Selection: Choose high-quality, low-loss dielectric materials that can support the fine features and high wiring density of HDI PCBs.

  2. Impedance Control: Ensure proper impedance control to maintain signal integrity and reduce signal reflections, especially in high-speed designs.

  3. Via Placement: Optimize via placement to minimize the impact on signal routing and to ensure reliable connections between layers.

  4. Thermal Management: Consider the thermal requirements of the design and incorporate appropriate thermal management techniques, such as thermal vias and heat spreaders.

  5. DFM Guidelines: Follow design for manufacturability (DFM) guidelines provided by the PCB manufacturer to ensure the design can be reliably manufactured and assembled.

Future Trends in HDI PCB Technology

As electronic devices continue to become more advanced and compact, HDI PCB technology is expected to evolve to meet the growing demands:

  1. Increased Wiring Density: Future HDI PCBs may feature even finer lines and spaces, smaller vias, and higher layer counts to accommodate more complex designs in smaller form factors.

  2. Advanced Materials: The development of new, high-performance dielectric materials with lower loss tangents and higher thermal stability will enable HDI PCBs to operate at higher frequencies and temperatures.

  3. 3D Packaging: The integration of HDI PCBs with 3D packaging technologies, such as package-on-package (PoP) and system-in-package (SiP), will allow for even greater miniaturization and functionality.

  4. Embedded Components: The incorporation of embedded active and passive components within the PCB substrate will further increase the wiring density and reduce the overall size of the board.

  5. Intelligent PCBs: The integration of sensors, processors, and other intelligent components into HDI PCBs will enable the development of smart, self-monitoring electronic systems.


  1. What is the difference between HDI PCBs and conventional PCBs?
    HDI PCBs have a higher wiring density per unit area compared to conventional PCBs, achieved through the use of finer lines and spaces, smaller vias, and capture pads. This allows for more complex designs in a smaller form factor.

  2. What are the main types of vias used in HDI PCBs?
    The two main types of vias used in HDI PCBs are microvias, which are blind or buried vias with a diameter of less than 150 μm, and buried vias, which connect inner layers of the PCB without penetrating the outer layers.

  3. What are the benefits of using HDI PCBs?
    The benefits of using HDI PCBs include miniaturization, improved electrical performance, enhanced functionality, and potential cost reduction through the reduction of components and interconnections.

  4. In which industries are HDI PCBs commonly used?
    HDI PCBs are commonly used in industries that require high-performance, compact electronics, such as consumer electronics, telecommunications, aerospace and defense, medical devices, and automotive electronics.

  5. What are some key design considerations for HDI PCBs?
    Key design considerations for HDI PCBs include material selection, impedance control, via placement, thermal management, and adherence to design for manufacturability (DFM) guidelines provided by the PCB manufacturer.


HDI PCBs have revolutionized the electronics industry by enabling the development of compact, high-performance devices that meet the growing demands of modern applications. With their higher wiring density, smaller vias, and advanced manufacturing processes, HDI PCBs offer numerous benefits, including miniaturization, improved electrical performance, and enhanced functionality.

As technology continues to advance, HDI PCBs are expected to evolve, incorporating even finer features, advanced materials, and innovative packaging techniques. By staying at the forefront of HDI PCB technology, designers and manufacturers can create cutting-edge electronic devices that push the boundaries of what is possible in terms of size, performance, and functionality.