In high-frequency PCB design, the choice of laminate material directly impacts performance, reliability, and long-term functionality. Among the premium choices available today, Rogers laminates stand out for their excellent electrical properties and thermal stability. In 2025, with the surge of 5G, automotive radar, and aerospace innovation, Rogers materials are more relevant than ever. This guide explores what Rogers laminates are, why they matter, and how to use them effectively in your PCB designs.
1. What Are Rogers Laminates?
Rogers laminates are advanced circuit board substrates manufactured by Rogers Corporation, specifically engineered for high-frequency and high-performance electronic applications. Unlike the widely used FR4, which is glass-reinforced epoxy laminate, Rogers materials are made from hydrocarbon ceramic or PTFE composites. Their consistent dielectric constant (Dk), low loss tangent (Df), and excellent thermal conductivity make them ideal for RF, microwave, and high-speed digital PCBs.
2. Popular Types of Rogers Laminates
Each Rogers laminate series offers unique features for different application needs:
- RO4350B: Known for low loss and excellent dimensional stability. A go-to for RF applications.
- RO4003C: Similar to RO4350B but lower cost; suitable for less critical RF designs.
- RO3003: Extremely low dielectric loss, ideal for advanced microwave circuits.
- RT/duroid 5880 & 6002: PTFE-based with ultra-low loss, used in aerospace and radar systems.
👉 Choosing the right Rogers laminate depends on your operating frequency, budget, and thermal requirements.
3. Applications of Rogers Laminates in 2025
Rogers laminates are preferred in industries where signal integrity and reliability are mission-critical:
- 5G infrastructure: Base stations, antennas, mmWave components
- Aerospace and defense: Radar systems, satellites, avionics
- Automotive electronics: Radar modules for ADAS, V2X communication
- High-speed digital: Routers, data centers, network equipment
4. Benefits of Using Rogers Laminates
- Consistent dielectric constant across frequency and temperature ranges
- Low signal loss, especially critical above 1 GHz
- Excellent heat resistance and thermal conductivity
- Lower Z-axis expansion, reducing risk of delamination or via cracking
- Ideal for multilayer RF and hybrid stack-up designs
5. Design Tips for PCBs with Rogers Laminates
Designing with Rogers laminates requires a more refined approach than with FR4. Here are essential tips to ensure signal integrity, thermal performance, and manufacturability:
5.1. Choose the Right Laminate for Your Frequency
- RO4003C or RO4350B is ideal for 1–10 GHz applications.
- RO3003 or RT/duroid 5880 are better for frequencies above 10 GHz.
- Match Dk and Df values to your impedance targets.
5.2. Use Proper Stack-up Configuration
- Work with your PCB manufacturer to build a controlled impedance stack-up.
- Include Rogers materials in signal layers, and cheaper FR4 cores for power or ground when possible.
- Maintain symmetry in multilayer designs to reduce warpage.
5.3. Maintain Tight Trace Width and Spacing Tolerances
- Rogers laminates allow precise impedance control, but that means tight tolerances matter more.
- Use simulation tools (e.g., Polar Si9000, HyperLynx) to validate trace width and spacing.
5.4 Avoid Right Angles in Signal Routing
- Avoid sharp corners or 90° trace bends, which cause signal reflections and EMI.
- Use 45° angles or smooth arc routing for better signal flow.
5.5 Optimize Via Design
- Minimize via transitions, especially in RF paths.
- Use backdrilled vias or blind/buried vias for critical layers.
- Consider via stub removal to reduce parasitic effects.
5.6 Plan for Thermal Management
- Rogers materials typically have better thermal conductivity, but high-power designs still need attention.
- Use thermal vias, heatsinks, or metal-backed substrates for heat dissipation.
5.7 Match Dielectric and Copper Thickness
- Choose dielectric thickness to control impedance and crosstalk.
- Standard prepregs and core thickness options are available in Rogers data sheets.
- For RF, thinner copper (1/2 oz or 1 oz) is often preferable to minimize skin effect.
5.8 Incorporate Ground Planes and Stitching
- Ensure solid ground planes are placed under high-speed signal traces.
- Use via stitching around signal paths and antennas to reduce noise and radiation.
5.9 Validate with Prototypes
- Rogers designs benefit greatly from early prototyping.
- Test for insertion loss, return loss, and signal integrity before moving to mass production.
6. Rogers Laminate PCB Manufacturing Considerations
- Higher lamination temperature required compared to FR4
- Careful hole drilling and copper plating to avoid resin cracking
- Plasma surface treatment may be required for PTFE-based materials
- Use of ENIG or immersion silver for better RF surface performance
7. Rogers Laminates Pricing in 2025
| Laminate Type | Price Range (Material Only) | Fabricated PCB (Est.) |
| RO4350B | $8 – $15 per sheet | $50 – $120 per m² |
| RO4003C | $6 – $12 per sheet | $40 – $100 per m² |
| RO3003 | $12 – $20 per sheet | $80 – $150 per m² |
| RT/duroid 5880 | $18 – $30 per sheet | $100 – $180 per m² |
KingSunPCB offers competitive pricing with material in stock and expert engineering support.
8. Where to Buy Rogers PCB Laminates or Order Fabrication
Choosing the right fabrication partner is crucial:
Why choose KingSunPCB:
- In-stock RO4350B, RO4003C, RO3003
- Expert support in RF stack-up design
- Free impedance simulation
- Fast prototyping and volume production
9. Conclusion
In the world of high-speed, high-frequency PCB design, Rogers laminates are an elite solution. With excellent electrical performance and thermal reliability, they are perfect for demanding applications in 2025 and beyond. Partner with an experienced manufacturer like KingSunPCB to fully harness the advantages of Rogers-based PCBs in your next innovation.