Halogen Free PCB

What is Halogen-Free PCB?

A Halogen-Free PCB (Printed Circuit Board) is a circuit board manufactured using materials with very low levels of chlorine and bromine, as defined by IEC standards. These elements are commonly found in traditional PCB laminates, flame retardants, solder masks, and inks. By reducing halogen content, halogen-free PCBs help minimize toxic emissions, improve safety, and support environmentally responsible electronics manufacturing. According to IEC 61249-2-21, halogen-free materials contain less than 900 ppm of chlorine and bromine individually, with a combined total below 1500 ppm.

At Sierra Assembly Technology, Inc., we provide halogen-free PCB fabrication and PCB assembly services for manufacturers seeking safer, compliant, and high-performance circuit boards. Our team supports U.S.-based companies across multiple industries with reliable production, consistent quality, and full engineering support from design through delivery.

Why Halogen-Free PCBs Are Important

Halogen-containing materials can release toxic and corrosive gases when exposed to high temperatures during soldering, product malfunction, or electronic waste processing. These emissions can negatively impact manufacturing personnel, end users, and the environment.
Halogen-free PCB manufacturing helps address these concerns by:

• Reducing toxic gas emissions during production and disposal
• Improving workplace safety in electronics manufacturing environments
• Supporting corporate sustainability initiatives
• Aligning with global environmental and material compliance requirements

For companies focused on long-term reliability, product safety, and environmental responsibility, halogen-free PCBs offer a practical and forward-looking solution. Learn more about halogen-free PCBs or consult our team for expert guidance.

Health & Environmental Risks of Halogens in PCBs

Halogens such as bromine and chlorine are commonly used in traditional PCB flame retardants. When heated, these substances can release hazardous byproducts including hydrogen bromide and hydrogen chloride. Exposure to these substances may cause:

• Respiratory irritation and breathing difficulties
• Skin and eye irritation
• Corrosion of electronic components
• Long-term environmental contamination

By using halogen-free PCB materials, manufacturers significantly reduce these risks while maintaining electrical and mechanical performance.

Key Features of Halogen-Free PCBs

Feature	Benefit
Reduced Toxic Emissions	Minimizes harmful fumes during assembly, operation, and recycling
Safer Manufacturing	Improves safety for production and assembly personnel
Regulatory Alignment	Supports global environmental and material standards
Fire-Resistant Performance	Uses non-halogen flame retardants
Broad Application Compatibility	Suitable for the same applications as standard PCBs

Halogen-Free PCB vs Traditional PCB Materials

Comparison Area	Halogen-Free PCB	Traditional PCB
Material Composition	No chlorine or bromine compounds	May contain halogen-based flame retardants
Toxic Emissions	Low risk during heating or disposal	Can release hazardous fumes
Environmental Impact	Lower environmental footprint	Higher environmental burden
Regulatory Compatibility	Supports compliance initiatives	May require additional controls
Electrical Performance	Comparable to standard PCBs	Well-established performance

Challenges of Designing Halogen-Free PCBs

While halogen-free PCBs provide many benefits, they also require careful design and manufacturing consideration:

• Material Selection: Halogen-free laminates must match electrical and thermal performance needs.
• Signal Integrity: Some materials have different dielectric properties affecting high-speed signals.
• Thermal Management: Heat dissipation characteristics may vary by material type.
• Manufacturing Process Adjustments: Fabrication and soldering profiles may need optimization.
• Cost Factors: Certain halogen-free materials can have higher initial costs.

At Sierra Assembly, our PCB Design for Manufacturability (DFM) reviews help minimize these challenges early in the process.

Common Applications of Halogen-Free PCBs

Halogen-free PCBs are widely used in applications where safety, reliability, and environmental responsibility are critical:

Industry / Application	Why Halogen-Free PCBs Are Used
Consumer Electronics	Reduced exposure risks for end users
Telecommunications Equipment	Improved safety in enclosed environments
Medical Electronics	Safer materials for sensitive settings
Automotive Electronics	Enhanced reliability and safety
Industrial Automation	Improved worker safety
Aerospace & Defense	High reliability with controlled materials
LED Lighting Systems	Reduced environmental impact
Renewable Energy Systems	Long-term reliability in harsh conditions
Data Centers & Networking	Safer operation in high-density installations

Halogen-Free PCB Fabrication Process

The halogen-free PCB fabrication process closely follows standard PCB manufacturing practices, with strict control over materials and processing. Fabrication Steps:

1. Design & Layout – CAD-based design with signal integrity and manufacturability considerations

2. Material Selection – Halogen-free laminates, solder masks, and surface finishes

3. Substrate Preparation – Panel cutting and surface preparation

4. Copper Deposition & Etching – Formation of traces and pads

5. Lamination – Multilayer stacking and bonding

6. Drilling & Via Plating – Electrical interconnections between layers

7. Solder Mask Application – Protective halogen-free coatings

8. Component Assembly – Placement using halogen-free solder materials

9. Soldering – Reflow or wave soldering

10. Testing & Inspection – Electrical, continuity, and functional tests

11. Surface Finish – ENIG, immersion silver, or OSP

12. Final Inspection – Quality verification

13. Packaging & Delivery – Prepared for shipment or integration

Get Your Halogen-Free PCB Quote today. Our experts will help you with custom solutions, precise specifications, and reliable manufacturing. Connect with our team to start your project with confidence.

Halogen-Free PCB Assembly Considerations

Successful halogen-free PCB assembly requires close control of soldering, thermal profiles, and inspection methods. Sierra Assembly supports halogen-free PCB assembly with:

• Optimized soldering profiles
• Material compatibility verification
• Comprehensive PCB testing and inspection
• Design for Manufacturability (DFM) support

This ensures consistent yields and reliable performance in production.

Why Choose Sierra Assembly for Halogen-Free PCBs

Sierra Assembly Technology provides halogen-free PCB fabrication and assembly services built on experience, quality systems, and responsive support.
Our customers benefit from:

• Proven expertise with halogen-free materials
• Strong DFM-driven engineering support
• Reliable PCB assembly services
• Comprehensive testing and inspection
• Consistent quality and traceability
• Clear communication and technical guidance

Partner With a Trusted Halogen-Free PCB Manufacturer

As environmental standards continue to evolve, halogen-free PCBs are becoming a preferred choice for responsible electronics manufacturing. Sierra Assembly Technology delivers safe, compliant, and high-performance halogen-free PCBs that support long-term product success.

Contact our team to discuss your halogen-free PCB fabrication or assembly requirements and receive expert guidance from start to finish.