Aluminium-Clad HPF Power PCB Design

I’m developing a compact, aluminium-clad SMD PCB that will live directly on mains, so every detail must be right first time. The board sits on 1 mm aluminium with 25 µm copper, accepts 220-260 VAC and has to deliver a rock-solid 144 VDC at 300-350 mA. Power-factor must stay high thanks to a hybrid DOB topology, while the protection network must survive 6 kV surges and automatically cut in on both high- and low-voltage events. Everything must be RoHS-compliant. Because the board ultimately feeds a power-supply module, thermals and creepage/clearance are just as critical as the electrical design. I’m looking for a clean, production-ready package that lets me hand Gerbers straight to my fabricator and have parts placed with confidence. Deliverables • Complete schematic with component values and reference designators • Layer-stack and PCB layout (Altium, KiCad, or comparable) matching 1 mm Al-clad / 25 µm Cu spec • Gerber, NC-Drill, pick-and-place files, and 3D step model • Bill of materials with supplier links (RoHS parts only) • Brief design report confirming surge, OVP/UVP, and thermal calculations Acceptance criteria – 6 kV surge withstand verified by simulation or past test data – Output 144 V ± 5 % across 300-350 mA load range, 220-260 VAC input – PF ≥ 0.9 at nominal load – Meets IPC creepage/clearance for mains equipment and RoHS declaration included If you’ve tackled similar high-voltage aluminium-clad boards and can turn around a clean, manufacturable design, I’d like to review your approach and timeline.

Project ID: 40375987