In today’s high-frequency, high-reliability industries—such as aerospace, automotive radar, and satellite communications—engineers require PCB materials that deliver ultra-low dielectric loss, dimensional stability, and consistent dielectric performance.
Among the leading RF materials, Taconic TLY-5 stands out as a very low Dk, low-loss PTFE-based laminate engineered for next-generation microwave and millimeter-wave circuit designs.
1. Overview: What Makes TLY-5 Exceptional
Taconic TLY-5 is an aerospace-grade RF substrate designed for microwave, radar, and millimeter-wave applications operating up to and beyond 77 GHz.
It uses very lightweight woven fiberglass reinforcement, which provides dimensional stability far superior to that of chopped-fiber PTFE composites—ensuring high yield and consistent performance in volume PCB manufacturing.
With a dielectric constant range of 2.17 to 2.40 (tunable per customer requirement) and an ultra-low dissipation factor of 0.0009 at 10 GHz, TLY-5 offers superior electrical characteristics that make it ideal for high-precision, low-loss RF circuits.
2. Key Features and Benefits
🔹 Ultra-Low Dielectric Constant (Dk)
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Dk range: 2.17 – 2.40, customizable within ±0.02 for specific thicknesses.
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Enables excellent impedance control and stable phase performance up to Ka, E, and W frequency bands.
🔹 Lowest Dissipation Factor (Df)
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Df ≈ 0.0009 @ 10 GHz, minimizing insertion loss even at millimeter-wave frequencies (up to 77 GHz).
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Ensures outstanding signal integrity for radar and satellite systems.
🔹 Dimensional Stability
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The woven fiberglass structure provides mechanical stability superior to chopped fiber materials, improving fabrication yields in multilayer PCB production.
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Exhibits minimal expansion under heat and pressure (X: 26 ppm/°C, Y: 15 ppm/°C).
🔹 High Peel Strength
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Excellent copper adhesion (up to 3.04 N/mm) ensures strong layer bonding, even after thermal stress cycles.
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Compatible with standard PCB lamination and soldering processes.
🔹 Low Moisture Absorption
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With only 0.02% moisture uptake, TLY-5 ensures stable electrical characteristics under varying humidity conditions—crucial for aerospace and radar systems.
🔹 Laser-Ablatable Surface
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Supports laser via formation and microvia drilling, making it suitable for advanced HDI RF designs and high-density multilayer boards.
3. Typical Applications
Taconic TLY-5 is trusted in aerospace, defense, automotive radar, and high-frequency communications due to its exceptional RF properties and process consistency.
| Application | Description |
|---|---|
| Automotive Radar (77 GHz) | Enables low-loss radar sensor modules with reliable millimeter-wave signal transmission. |
| Satellite & Cellular Communications | Ideal for ground-based and orbital communication systems requiring phase stability. |
| Power Amplifiers (PA) | Supports high-efficiency, low-loss power delivery for RF amplifiers and transmitters. |
| Low-Noise Circuits (LNBs, LNAs, LNCs) | Maintains low insertion loss and high signal clarity in noise-sensitive designs. |
| Aerospace Electronics | Suitable for avionics, phased-array antennas, and radar detection modules. |
| Ka, E, and W Band Devices | Provides stable performance for microwave and millimeter-wave applications up to 110 GHz. |
4. Detailed Material Properties
| Category | Property | Typical Value | Test Method |
|---|---|---|---|
| Electrical | Dielectric Constant (10 GHz) | 2.20 ± 0.02 | IPC-650 2.5.5.5 |
| Dissipation Factor (10 GHz) | 0.0009 | IPC-650 2.5.5.5 | |
| Volume Resistivity (After Heat/Humidity) | 10¹⁰ MΩ·cm | IPC-650 2.5.17.1 | |
| Surface Resistivity (After Heat/Humidity) | 10⁸ MΩ | IPC-650 2.5.17.1 | |
| Thermal | Thermal Conductivity | 0.22 W/m·K | ASTM F433 |
| CTE (X/Y/Z) | 26 / 15 / 217 ppm/°C | ASTM D3386 | |
| Mechanical | Peel Strength (1 oz Cu, C1 Copper) | 3.04 N/mm (17 lb/in) | IPC-650 2.4.8 |
| Flexural Strength (MD/CD) | 96.91 / 89.32 N/mm² | IPC-650 2.4.4 | |
| Young’s Modulus (MD) | 9.65×10³ N/mm² | ASTM D3039 | |
| Poisson’s Ratio | 0.21 | ASTM D3039 | |
| Density | 2.19 g/cm³ | ASTM D792 | |
| Environmental | Moisture Absorption | 0.02% | IPC-650 2.6.2.1 |
| NASA Outgassing (TML / CVCM / WVR) | 0.01% / 0.01% / 0.01% | NASA 1124 | |
| Safety | Flammability Rating | UL 94 V-0 | UL-94 |
5. Standard Thicknesses and Panel Sizes
Thickness Options:
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0.0035″ (0.09 mm), 0.0050″ (0.13 mm), 0.0075″ (0.19 mm),
0.010″ (0.25 mm), 0.020″ (0.51 mm), 0.030″ (0.76 mm), 0.031″ (0.79 mm), 0.060″ (1.52 mm)
Available Sheet Sizes:
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12” × 18” (305 × 457 mm)
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16” × 18” (406 × 457 mm)
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18” × 24” (457 × 610 mm) — Standard size
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16” × 36” (406 × 914 mm)
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24” × 36” (610 × 914 mm)
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18” × 48” (457 × 1220 mm)Custom thicknesses in 0.005″ increments available upon request.
6. TLY-3FF: The Flexible Variant
Taconic also offers TLY-3FF, a highly flexible version of TLY-5 designed for circuits requiring bend radius or mechanical flexibility.
It maintains the dimensional stability of TLY-5 while offering lower loss and better laser via formation compared to traditional chopped-fiber laminates—ideal for flexible antennas and conformal RF modules.
7. Conclusion
Taconic TLY-5 is a proven, aerospace-grade RF laminate that sets the standard for low-loss, low-Dk, and high-yield manufacturing in high-frequency PCB design.
With its dimensional stability, superior copper adhesion, and exceptional dielectric performance, it is the material of choice for automotive radar, satellite systems, aerospace electronics, and millimeter-wave communication devices.
For demanding RF engineers, TLY-5 ensures reliability, performance, and manufacturability—a true benchmark material in the Taconic TLY series.
