Today I'm showcasing a custom PCB built on Taconic TLX-6 —a high-volume antenna material designed for reliability in extreme environments.
This custom PCB was fabricated using Taconic TLX-6, a PTFE fiberglass laminate with a low and stable dielectric constant. Its excellent mechanical properties, radiation resistance, and exceptional PIM performance (below -160 dBc) make it ideal for radar systems, mobile communications, and microwave test equipment. With 102 components and 127 vias, this is the most complex board we've featured.
Key Takeaways
- Material: Taconic TLX-6 — PTFE fiberglass laminate
- Key Benefit: Excellent PIM values (< -160 dBc), radiation resistance, dimensional stability
- Board Size: 105mm x 98mm | Thickness: 0.2mm (ultra-thin)
- Construction: Double-sided, no solder mask on either side, white silkscreen on top
- Design: 102 components, 127 vias, 2 nets — a dense, complex RF design
- Quality: IPC-Class-2 with 100% electrical testing
- The Challenge: Reliability in Extreme Environments
A high-performance RF board was required by our customer for an application demanding exceptional reliability in severe conditions. The design needed to withstand vibration during space launch, high-temperature exposure, radiation in space, and extreme environments at sea. Additionally, excellent Passive Intermodulation (PIM) performance was critical.
TLX-6 was selected, a PTFE fiberglass laminate from Taconic's high-volume antenna material series. Here's why it was chosen:
Excellent PIM Performance
PIM values measured below -160 dBc were achieved —a critical requirement for sensitive communication systems where intermodulation distortion must be minimized.
Radiation Resistance and Low Outgassing
These properties are essential for space applications. The material has been recognized by NASA for its low outgassing characteristics, making it suitable for satellite and space-borne systems.
Excellent Mechanical & Thermal Properties
Resistance to creep was provided for PWBs bolted to housings experiencing high vibration during space launch. High-temperature exposure in engine modules was also withstood.
Low and Stable Dk
A tightly controlled dielectric constant was maintained across a wide frequency range, ensuring consistent electrical performance.
Dimensional Stability
Excellent dimensional stability was achieved, even when subjected to extreme temperature variations during flight or environmental cycling.
Low Moisture Absorption
Minimal moisture absorption was ensured, preventing performance drift in humid environments.
Board Specifications
| Feature |
Specification |
| Dimensions |
105mm x 98mm (±0.15mm) |
| Stackup |
35μm Cu / 0.089mm TLX-6 / 35μm Cu |
| Finished Thickness |
0.2mm (ultra-thin) |
| Trace/Space |
5/7 mils |
| Min Hole Size |
0.3mm |
| Surface Finish |
Immersion Gold |
| Solder Mask |
None (both sides) |
| Silkscreen |
White (top only) |
| Testing |
100% electrical |
| Standard |
IPC-Class-2 |
Design Statistics
| Metric |
Value |
| Components |
102 |
| Total Pads |
98 (61 through-hole, 37 SMT) |
| Vias |
127 |
| Nets |
2 |
The 2-net design with 127 vias indicates a highly complex RF circuit with extensive grounding and shielding structures. The high component count (102) suggests a sophisticated sub-system, likely an antenna array or complex microwave network.
Design Choices: Purpose-Built for Extreme Environments
No Solder Mask (Both Sides)
Solder mask was eliminated to prevent any potential dielectric loss or outgassing contributions—critical for space and aerospace applications.
White Silkscreen (Top Only)
White silkscreen was applied to provide clear component identification.
Immersion Gold Finish
Immersion gold was chosen to deliver a flat, solderable surface with excellent corrosion resistance.
0.2mm Ultra-Thin Construction
The ultra-thin construction enables lightweight designs—a critical advantage for space and aerospace applications where every gram matters.
Comparison: How TLX-6 Stacks Up
| Property |
TLX-6 |
Standard FR-4 |
PTFE (Typical) |
| PIM Performance |
< -160 dBc |
Poor |
Good |
| Radiation Resistance |
Excellent |
Poor |
Moderate |
| Dk Stability |
Excellent |
Moderate |
Good |
| Dimensional Stability |
Excellent |
Good |
Moderate |
| Moisture Absorption |
Low |
High |
Low |
| UL Rating |
94 V0 |
94 V0 |
94 V0 |
Why This Matters: TLX-6 offers exceptional PIM performance and radiation resistance, making it ideal for critical communication and radar systems in extreme environments.
Ideal Applications
- Radar systems requiring reliable performance
- Mobile communications infrastructure
- Microwave test equipment
- Microwave transmission devices
- Couplers, splitters, combiners, amplifiers, and antennas
Q: What makes TLX-6 suitable for space applications?
A: The material exhibits radiation resistance and low outgassing, and has been recognized by NASA for its suitability in space environments.
Q: What is PIM and why does it matter?
A: Passive Intermodulation (PIM) is distortion generated by non-linearities in passive components. Low PIM (< -160 dBc) is critical for sensitive communication systems to prevent interference.
Q: Why are there 127 vias with only 2 nets?
A: The high via count represents extensive grounding and shielding structures, creating a well-defined ground plane for the RF signals.
Q: What does "high-volume antenna material" mean?
A: TLX-6 is designed for high-volume production of antennas and RF components, offering consistency and reliability at scale.
Q: How does TLX-6 handle extreme environments?
A: The material resists creep under vibration, withstands high temperatures, maintains performance in radiation environments, and remains stable across wide temperature ranges.
Final Thoughts
Taconic TLX-6 delivers exceptional PIM performance, radiation resistance, and mechanical robustness in a lightweight, ultra-thin package. When your application demands reliability in the most extreme environments, this material delivers.
Got a radar or antenna project in mind? I'd love to hear about it.
— Sally
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