RF and microwave PCBs with Rogers, Teflon & specialty materials. Impedance-controlled designs for 5G, radar, satellite & defense applications.
Get RF PCB QuoteSpecialized materials for signals above 1 GHz
High frequency PCBs are circuit boards engineered to carry signals at frequencies above 1 GHz — and often up to 100+ GHz for millimeter-wave applications. Unlike standard FR-4 boards, HF PCBs use specialized dielectric materials with tightly controlled electrical properties: low dielectric constant (Dk), low dissipation factor (Df), and stable performance across temperature and frequency.
The key challenge at high frequencies is signal loss and impedance discontinuity. Standard FR-4 has a Dk of ~4.5 and Df of ~0.02, which causes unacceptable signal attenuation above 1–2 GHz. High frequency materials like Rogers RO4003C (Dk=3.38, Df=0.0027) or Teflon/PTFE (Dk=2.1, Df=0.001) dramatically reduce losses, enabling clean signal transmission at microwave and millimeter-wave frequencies.
At Mayio, we have extensive experience manufacturing RF PCBs for demanding applications. Our engineering team understands the unique design rules for HF boards: controlled impedance traces, grounded coplanar waveguides, via fencing, and material-specific stackup design. We work with all major HF material brands and can recommend the optimal material for your frequency range, loss budget, and cost target.
Choosing the right substrate for your RF application
| Material | Dk (10 GHz) | Df (10 GHz) | Typical Use |
|---|---|---|---|
| Rogers RO4003C | 3.38 ± 0.05 | 0.0027 | 5G, WiFi, general RF |
| Rogers RO4350B | 3.48 ± 0.05 | 0.0037 | Power amplifiers, RF front-ends |
| Rogers RO3003 | 3.00 ± 0.04 | 0.0013 | mmWave, 77 GHz automotive radar |
| Taconic TLY-5 | 2.20 ± 0.02 | 0.0009 | Ultra-low-loss, satellite comm |
| Isola I-speed | 3.40 ± 0.05 | 0.0028 | High-speed digital, mixed RF/digital |
| Megtron 7 | 3.40 ± 0.05 | 0.0020 | 400G networking, high-speed backplane |
Critical RF technology across industries
Base station antennas, massive MIMO panels, mmWave small cells, and 5G handsets operating at sub-6 GHz and mmWave bands.
Automotive ADAS radar (77 GHz), military surveillance radar, weather radar, and synthetic aperture radar (SAR).
VSAT terminals, LEO satellite transceivers, ground station equipment, and space-qualified RF assemblies.
WiFi 6E/7 access points, Bluetooth modules, LoRa/NB-IoT gateways, and Zigbee wireless systems.
MRI receiver coils, RF ablation systems, medical telemetry, and diagnostic imaging equipment.
Vector network analyzers, spectrum analyzers, signal generators, and RF test fixtures up to 67+ GHz.
Competitive pricing for RF and microwave boards
| Specification | Prototype (5 pcs) | Small Batch (25 pcs) | Production (100 pcs) |
|---|---|---|---|
| Rogers RO4003C 2-layer 1.524mm, 1oz Cu, HASL |
$45.00 | $18.00/pc | $8.50/pc |
| Rogers RO4350B 4-layer 1.524mm, 1oz Cu, ENIG |
$85.00 | $35.00/pc | $15.00/pc |
| Rogers RO3003 2-layer 0.508mm, 1oz Cu, ENIG |
$65.00 | $28.00/pc | $12.00/pc |
| Mixed Dielectric (Rogers + FR-4) Hybrid stackup, 4-layer |
$120.00 | $50.00/pc | $22.00/pc |
* Prices vary based on board size, layer count, impedance requirements, and surface finish. Contact us for exact quotes.
Advanced manufacturing for demanding RF applications
Tight ±5% impedance control using Polar Si9000 field solver. Microstrip, stripline, and coplanar waveguide structures.
Controlled impedance trace widths down to 3 mil. Tight tolerance copper etching for consistent RF performance.
Precision backdrilling to remove unused via stubs. Via fence design for isolation between RF channels.
Authorized Rogers converter. Stock of RO4003C, RO4350B, RO3003, and Taconic materials for fast turnaround.
Vector network analysis up to 67 GHz. S-parameter measurements and time-domain reflectometry (TDR) available.
High-reliability manufacturing to IPC-6012 Class 3 standards for aerospace, defense, and mission-critical applications.
Expert engineering from design to delivery
Our RF engineers review your stackup, impedance targets, and material selection. DFM analysis for high-frequency performance.
Specialized handling for PTFE and hydrocarbon ceramics. Controlled lamination cycles for optimal bond strength.
Controlled etching, via drilling, backdrilling, and surface finish. Tight tolerances maintained throughout.
Impedance testing, S-parameter measurement, and dimensional inspection. Full test report with every order.
Expert answers about high frequency PCB manufacturing
A high frequency PCB is a circuit board designed to operate at frequencies above 1 GHz, using specialized low-loss dielectric materials (such as Rogers, Teflon/PTFE, or ceramic-filled hydrocarbons) instead of standard FR-4. These materials maintain stable dielectric constant and low loss tangent at high frequencies, enabling reliable signal integrity for RF, microwave, and millimeter-wave applications.
Common high frequency PCB materials include Rogers RO4003C/RO4350B (hydrocarbon ceramic), Rogers RO3000 series (PTFE-based), Taconic TLY/TLX (PTFE glass), Isola I-speed/Itera (high-speed digital), and Megtron 6/7 (low-loss). Material choice depends on frequency range, loss requirements, and budget. Rogers RO4003C is the most popular for 5G and general RF applications.
High frequency PCBs are 3–10× more expensive than standard FR-4 boards. Prototype pricing starts from $30–$50 for small boards (100×100mm, 2-layer). Production pricing ranges from $5–$20 per board depending on size, layer count, material type, and copper weight. Rogers RO4003C offers the best balance of performance and cost.
High frequency PCBs are used in 5G base stations and handsets, radar systems (automotive, military, weather), satellite communications, GPS/GNSS modules, WiFi 6E/7, IoT wireless modules, microwave backhaul, medical imaging (MRI), and test & measurement equipment.
Yes. We provide tight impedance control (±5% tolerance) using Polar Si9000 field solver calculations. We control trace width, dielectric thickness, and copper weight to achieve exact impedance targets for microstrip, stripline, and coplanar waveguide structures.
Our RF engineers are standing by to help with material selection, stackup design, and impedance control.