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How to Design High Voltage PCBs? Tutorial 2023

Views: 531 Author: Site Editor Publish Time: 2023-04-26 Origin: Site

High-voltage PCB design makes printed circuit boards that work safely and well at high voltage levels. High-voltage PCBs find widespread application in electrical infrastructure, high-voltage power sources, and healthcare technology. In this blog we shall discuss some most important features of High voltage pcb.

What is High Voltage PCB?

Once you have a firm grasp on what "high voltage" means conceptually, we can go forward with the specifics of the high-voltage PCB design. Very exciting! "High voltage" usually refers to voltages greater than one thousand volts (1 kV). PCBs can safely and reliably manage large voltages if the right measures are taken and the right design is used.

High-Voltage Printed Circuit Boards: Picking the Right Material!

When making a PCB for high voltage, the material you use is crucial. The identification of reliable and long-lasting materials suitable for the fabrication of high-voltage printed circuit boards (PCBs) capable of withstanding exposure to elevated voltage levels is a noteworthy advancement.

 This information is of high quality. The salient feature concerns the presence of varied options for producing high-voltage printed circuit boards (PCBs), encompassing ceramic, glass, and high-temperature laminates, among others.

Creepage and Clearance Distances:

Creepage and clearance distances are two of the most important things to consider when designing a high-voltage PCB. Creepage distance is the shortest distance along the surface of a PCB between two conductive parts.

On the other hand, clearance distance is the smallest distance through the air between two conductive parts on a PCB. Both lengths are essential to ensure that high voltage doesn't arc or jump between conductive parts, which can damage the PCB or other equipment.

Things to think about with PCB layout:

The layout of the high voltage printed circuit board is critical to ensure the safe and reliable operation of the printed circuit board at high voltage levels.

 High Voltage PCBs

Some important considerations in high-voltage PCB layout are separating high-voltage and low-voltage components to prevent crosstalk and interference, keeping traces short and straight to minimize impedance and reduce the risk of voltage drop, and using a ground plane to help protect the PCB and reduce interference.

 Using multiple layers to help route high-voltage lines and reduce noise.

Component choice is another important consideration when designing a high-voltage PCB. High-voltage PCBs need parts that can handle high voltage levels and meet safety standards. High-voltage capacitors, transformers, and resistors are popular high-voltage parts.

Power source Design: 

In high voltage PCB design, the power source design is fundamental. A well-made power source can help control the voltage and ensure the PCB works safely and competently. When designing a power supply, it is important to use the right voltage regulators, the right generator, and to ground everything properly.

EMC and EMI are two critical factors to think about while designing a high-power printed circuit board.

High-voltage PCBs can make a lot of EMI, which can cause other electrical equipment to break down or stop working. EMI and EMC can be kept to a minimum with proper insulation, filtering, and grounding.

The test and the check:

To ensure a high-voltage PCB works safely and effectively, it must be tested and checked. Among the most popular tests are those for high voltage, insulation resistance, and dielectric strength. These checks can help determine if the PCB has any problems and ensure it meets safety standards.

PCB inspection is a critical step in making a printed circuit board. It checks the quality and dependability of the board. Most of the time, automated inspection systems are used to check PCBs. These systems can find problems like missing parts, parts that aren't lined up right, solder problems, and other production problems.

Different ways to check PCBs:

There are different kinds of PCB inspections, and each one does something different to ensure the PCB is good quality and reliable. Some of the most popular ways to check for PCBs are:

Inspection by sight:

Visual inspection is the most basic type of PCB inspection. It includes looking at the board by hand for problems or flaws that are easy to see. Usually, a trained technician does this check. The technician looks at the board with a magnifying glass for missing or misaligned parts, solder defects, and other problems.

Visual checking is a cheap and effective way to find certain flaws, but it is only sometimes accurate because people can make mistakes or get tired. Because of this, automated inspection systems are often used in addition to eye inspection to ensure things are accurate and consistent.

Automated Inspection: 

Automated inspection is a more advanced type of PCB inspection that uses computer-controlled tools to scan the PCB for problems and flaws.

Automated inspection systems are very exact and reliable. They can find many problems, such as missing or misaligned parts, bad solder, and other problems with making the product. Automated inspection systems are also faster than eye inspection, which means more can be done in less time and for less money.

Benefits of PCB Inspection: 

PCB inspection is vital for ensuring the PCB's quality and reliability. PCB inspection can help avoid costly rework and repairs and reduce the chance that a product will break down in the field by finding and identifying problems and flaws early on in the manufacturing process.

Why PCB testing is good for product quality?

PCB testing can assist enhance the quality and dependability of the PCB by detecting and addressing faults and flaws early on in the production process. This helps to ensure that the PCB is produced to the highest possible standards. This can help keep products from breaking and reduce the need for fixes and rework, which can be expensive.

Increased Efficiency:

 PCB checking can help improve efficiency and cut production costs by finding problems and flaws early in manufacturing. This can help companies make high-quality PCBs faster and for less money.

Compliance with Standards: 

A PCB inspection is often needed to meet regulatory standards, such as IPC-A-610, which explains the criteria for what makes an electronic assembly acceptable. By inspecting PCBs, manufacturers can ensure that their goods meet these standards and can be used safely and reliably in various ways.

Safety is the most important thing to consider when designing a high-voltage PCB. Designers must make sure that the PCB works safely and doesn't put users or other tools at risk. This means following safety rules, using suitable materials and parts, and ensuring the wiring is properly grounded and insulated.

Thoughts on Manufacturing: 

You need special tools and methods to make high-voltage PCBs. The people who make PCBs must have worked with high-voltage materials before and be able to meet strict safety standards. Also, high-voltage PCBs must be tested and checked more often to meet safety standards.

Compliance with regulations: 

The design of a high-voltage PCB must meet UL, CSA, and IEC standards, among others. These guidelines help ensure that high-voltage PCBs can be used safely and reliably in various ways. These standards are essential for designers to understand and use in their work.

Thermal Management: 

High-power PCBs can make a lot of heat, hurting their performance and dependability. Ensuring the PCB works safely and well depends on how well it handles heat. This could mean using heat sinks, fans, and other ways to eliminate heat.

Circuit safety:

 When making PCBs for high voltage, circuit protection must be taken into account. This could mean adding overcurrent protection, overvoltage protection, and other safety steps to keep the PCB and equipment from getting damaged.


Inspection is one of the critical factors to consider when making a high-voltage PCB. High-voltage PCBs must work consistently for long periods and in harsh environments. This means using high-quality materials and parts, putting robust testing and proof methods in place, and ensuring the machine is properly maintained and fixed.

Future Trends:

High-voltage PCB design is an area that constantly changes as new technologies and materials emerge. Future trends in high-voltage PCB design include using advanced materials like graphene and adding intelligent technologies like sensors and control systems.


High voltage PCB design is a challenging and complex area requiring specialized knowledge and skills. Designers have to think about several things, such as the choice of materials, the layout, the choice of components, the design of the power supply, EMI/EMC issues, testing, safety, manufacturing, and compliance with regulations. But with the proper planning and execution, high-voltage PCBs can be made safely and consistently so they can be used in various ways.

About The Author

I am the Engineering and Sales supervisor working in Victorypcb from 2015. During the past years, I have been reponsible for all oversea exhibitions like USA(IPC Apex Expo), Europe(Munich Electronica) and Japan(Nepcon) etc. Our factory founded in 2005, now have 1521 clients all over the world and occupied very good reputation among them.


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