Industrial Automation PCB

PCB Solutions for
Industrial Automation

From PLCs and servo drives to industrial IoT and safety controllers — robust, high-current PCBs engineered for 24/7 operation in harsh factory environments.

IPC Class 2 / 3 IP67 Compatible -40°C to +125°C EMC Tested
125°C
Max operating temperature
20oz
Max copper weight
32L
Max layer count
24/7
Continuous operation rating
20oz
Max copper weight
-40°C
Min operating temperature
8h
DFM review turnaround
IPC 3
Build standard on request
Applications

Where our PCBs run
in industrial systems

From the factory floor to outdoor substations — we supply boards for the full spectrum of industrial electronics.

01

PLC & Safety Controllers

High-Tg FR4 and polyimide multilayer boards up to 30 layers for PLCs and safety controllers, with conformal-coat ready stackups for IP-rated enclosures.

02

Motor Drives & Servo Amplifiers

Heavy copper boards up to 20 oz with custom thermal via arrays sustaining 400A+ current paths for servo amplifiers and motor drive electronics.

03

HMI & Touch Panel Controllers

HDI multilayer boards for compact touch-panel human-machine interfaces mounted directly on machine enclosures across the factory floor.

04

Industrial Power Conversion

Heavy copper multilayer boards engineered for AC-DC and DC-DC power conversion modules feeding motor drives and control cabinets.

05

IIoT Edge Gateways

8-layer any-layer HDI boards with Ethernet, CAN, RS-485 and Wi-Fi 6 connectivity, rated -40°C to +85°C with IP67 potting-compatible stackups.

06

Robot & Motion Controllers

HDI and rigid-flex boards for compact robot joint controllers and motion-control cards integrated inside factory automation cells.

07

Sensor & Actuator Interfaces

Standard multilayer PCBs for proximity sensor, encoder and pneumatic actuator interface modules operating on the production line.

08

Outdoor Substation Controls

Conformal-coated IPC Class 3 boards built to -40°C to +125°C for outdoor electrical substation monitoring and control panels.

The Engineering Challenge

Why industrial automation PCBs
require a different standard

Factory automation equipment runs continuously, often in extreme conditions. Board failures cause production downtime that costs thousands per minute.

01

Harsh Environments — 24/7 Operation

Industrial PCBs face continuous temperature cycles, high humidity, vibration, EMI and chemical contamination. Boards in motor drives and outdoor enclosures must maintain full performance across -40°C to +125°C without derating.

-40°C to +125°C · IP67 compatible · conformal coating
02

High Current & Thermal Management

Motor drives and power conversion boards carry currents from tens to hundreds of amperes. Standard 1 oz copper traces simply cannot sustain these loads. Heavy copper up to 20 oz and thermal via arrays are essential, not optional.

up to 20 oz copper · 400A+ · thermal via arrays
03

EMC & Functional Safety

Industrial environments generate significant electromagnetic interference. Boards must meet IEC 61000 immunity requirements, while safety-critical control circuits must comply with IEC 62061 (SIL) functional safety standards — with full documentation.

IEC 61000 EMC · SIL 2/3 · IEC 62061
Board Technologies

PCB technologies built
for the factory floor

Industrial applications demand boards that last. We match the right technology to your operating environment.

Motor Drives · Power Conversion

Heavy Copper PCB

Up to 20 oz finished copper for high-current motor drives, servo amplifiers and power distribution boards. Custom thermal via patterns and bus-bar integration capability to manage heat at the source.

up to 20 oz Cu 400A+ paths thermal via arrays
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PLC · Safety Controllers

High-Reliability Multilayer

High-Tg FR4 and polyimide multilayer boards for PLCs, safety controllers and industrial computers operating in harsh environments. Conformal coating pre-approved stackups available for IP-rated enclosures.

Tg 170–220°C up to 30 layers conformal-coat ready
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IIoT · Robotics · HMI

HDI & Rigid-Flex PCB

High-density interconnect and rigid-flex boards for compact IIoT gateways, robot joint controllers and touch-panel HMIs. Miniaturise without compromising the reliability demanded by 24/7 factory operation.

any-layer HDI rigid-flex 2.5/2.5 mil
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Technical Specifications

Built to automotive
specification.

Every parameter below is verified against IATF 16949 and IPC-A-600 Class 3 requirements. Full test reports and material traceability ship with every order.

  • 20oz
    Max copper weight
  • -40°C
    Min operating temperature
  • 30L
    Max layer count
  • ±5%
    Impedance tolerance
Request Capability Sheet →
ParameterAutomotive GradeStatus
Layer Count2 – 30 layersAvailable
Copper WeightUp to 20 oz finished copperAvailable
Operating Temperature-40°C to +125°CAvailable
Min. Trace / Space2.5 / 2.5 milAvailable
Surface FinishHASL / ENIG / ENEPIG / OSPAvailable
Controlled Impedance±5% tolerance, TDR verifiedAvailable
IPC Build StandardClass 2 default, Class 3 on requestAvailable
Conformal CoatingPre-approved stackups for IP67 assembliesAvailable
Lot TraceabilityFull lot level documentationAvailable
Quality & Compliance

Industrial-grade quality for demanding environments.

Factory automation PCBs must not fail. Our IPC Class 2/3 certified processes, full electrical test and conformal coating expertise ensure your boards keep production running.

ISO 9001 : 2015
Third-party audited quality management
IPC-A-600 Class 2 / 3
Industry-standard acceptability criteria
RoHS / REACH
EU hazardous substance compliance
UL E-File Listed
US and Canadian safety recognition

Testing & Inspection Methods

  • 100% Automated Optical Inspection (AOI)Every layer, every board
  • 100% Electrical Test (Flying Probe / Fixture)Open/short on all nets
  • X-Ray InspectionBGA and buried via integrity
  • Impedance Test with TDR±5% verified per production lot
  • Thermal Cycling -40°C to +125°CPer IEC 60068-2-14
  • Microsection & Cross-section AnalysisVia plating and barrel integrity
  • Current-Carrying Capacity VerificationOn heavy copper lots per IPC-2152
  • Conformal Coating InspectionUV-fluorescence verification post-coat
Case Studies

Projects we've delivered

Real automotive PCB challenges — and how we solved them.

Motion Control · Servo Drive

500A Servo Motor Drive Board

12-layer heavy copper board (10 oz) for a 500A industrial servo amplifier. Required bus-bar integration, custom thermal via array and IEC 60950 clearance on all HV traces.

10oz
Copper
500A
Rated current
0fail
4 yr field
Outcome

Zero thermal failures across 4 years of 24/7 industrial deployment. Customer reduced heatsink mass by 35% using our thermal via layout recommendation.

Safety PLC · SIL 2

Functional Safety Controller

16-layer IPC Class 3 board for a SIL 2 safety PLC. Required full FAI, IEC 62061 documentation package and lot-level component traceability.

16L
Layers
SIL 2
Safety level
FAI
1st submit
Outcome

FAI approved first submission. Safety documentation package accepted by TÜV assessor without queries. Now in volume production for 3 machine platforms.

IIoT · Edge Gateway

Multi-Protocol IIoT Gateway PCB

8-layer HDI board with simultaneous Ethernet, CAN, RS-485, Wi-Fi 6 and LoRa capability for a factory edge gateway. -40°C to +85°C rating, IP67 potting-compatible stackup.

8L
Layers
5protocol
Interfaces
IP67
Potting-ready
Outcome

98.6% first-pass yield on 5,000-unit run. Gateway boards have operated in outdoor installations for 2+ years with zero weather-related failures.

Why HanSphere

Why Tier-1 suppliers
choose us.

Automotive procurement teams need more than a PCB factory — they need a certified partner with documented processes, fast engineering response and the depth to solve problems before the production line.

20oz
Max copper weight

In-house heavy copper — no outsourcing

We press, plate and etch heavy copper boards entirely in-house. No third-party job-shop, no quality handoffs — your current-carrying traces are controlled from bare laminate to finished board.

8h
DFM turnaround

Engineering review before a single panel is made

Our industrial engineers check your stackup, copper distribution, thermal vias and clearances within 8 hours — catching issues before they become expensive field failures.

24/7
Production capacity

Ready for volume production and quick-turn

48-hour express prototypes for development, reliable 5–10 day standard lead times for production. Our facility runs 24/7 so your project doesn't wait.

DDP
40+ countries

Global supply chain, one partner

Door-to-door delivery to factory sites worldwide. English-speaking engineers and account managers on call for technical issues at any stage of your production run.

Get a Quote

Start your automotive
PCB project today.

Our industrial automation PCB engineering team will review your design and return a full DFM report and quote within 8 working hours.

  • DFM review included with every enquiry
  • NDA signed on request — standard practice
  • IATF 16949 documentation available
  • Response within 8 working hours
  • No commitment required to get a quote
Request Industrial PCB Quote All files encrypted · Max 80MB per upload · NDA available

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