Rogers RT/duroid 5880 High-Frequency PCB Material

Rogers RT/duroid 5880 is one of the most widely used microwave and millimeter-wave PCB substrates, known for its ultra-low dielectric loss and stable electrical performance. It is extensively applied in radar systems, satellite communications, 5G infrastructure, automotive radar, aerospace, and high-speed digital circuits.

In this article, KKPCB provides a comprehensive technical overview of RT/duroid 5880, covering:

• Material composition

• Electrical, mechanical, and thermal properties

• Available laminate formats

• Typical applications

• Comparison with other RF substrates

• Practical PCB design and manufacturing guidelines

• Frequently asked questions

1. What Is Rogers RT/duroid 5880?

Rogers RT/duroid 5880 is a ceramic-filled PTFE (polytetrafluoroethylene) composite laminate, specifically engineered for high-frequency RF and microwave PCB applications.

Material Composition

The substrate consists of:

• PTFE polymer matrix – provides excellent electrical insulation and thermal stability

• Proprietary inorganic ceramic filler – tailors dielectric properties while preserving PTFE advantages

This composite formulation delivers:

• Exceptionally stable dielectric constant across frequency and temperature

• Ultra-low dielectric loss

• Low Z-axis coefficient of thermal expansion (CTE)

• Good mechanical rigidity suitable for double-sided and multilayer PCBs

2. Dielectric Properties of RT/duroid 5880

Dielectric performance is the most critical parameter for RF PCB materials. RT/duroid 5880 excels in this area.

Key Dielectric Parameters

• Dielectric Constant (Dk): 2.20 ± 0.02

• Loss Tangent (Df) @ 10 GHz: 0.0009

Unlike many substrates whose Dk varies significantly with frequency, RT/duroid 5880 maintains consistent performance from microwave to millimeter-wave bands.

Electrical Advantages

• Easier impedance control

• Higher Q-factor circuit designs

• Lower insertion loss

• Improved signal integrity at high frequencies

This makes RT/duroid 5880 ideal for high-Q resonators, antennas, filters, and low-noise RF front-end circuits.

3. Electrical, Mechanical & Thermal Properties

Electrical Properties

• Volume Resistivity: 1 × 10¹⁴ ohm·cm

• Surface Resistivity: 5 × 10¹⁴ ohms

• Dielectric Strength: 3.0 × 10⁶ V/m

Mechanical Properties

• Flexural Strength: 20,000 psi (138 MPa)

• Tensile Strength: 10,000 psi (69 MPa)

• Compressive Strength: 30,000 psi (207 MPa)

• Density: 2.2 g/cm³

Thermal Properties

• Thermal Conductivity: 0.71 W/m·K

• Coefficient of Thermal Expansion (CTE): 17 ppm/°C

• Max Continuous Operating Temperature: 170°C

• Decomposition Temperature: >280°C

• Water Absorption: <0.02%

These characteristics ensure excellent dimensional stability, thermal reliability, and environmental resistance.

4. Available Forms & Thickness Options

Sheet Laminates

Standard Sheet Sizes

• 12 × 18 in

• 18 × 24 in

• 24 × 36 in

Standard Thicknesses

• 0.005″, 0.010″, 0.015″, 0.020″

• 0.025″, 0.030″, 0.060″, 0.125″

(Custom thicknesses available upon request)

Roll Laminates

• Widths: 12″, 24″, 48″

• Standard Length: 250 ft (76 m)

• Thickness Range: 0.005″ – 0.062″

This flexibility supports antenna arrays, large panels, and volume RF production.

5. Bonding & Multilayer PCB Options

Fusion Bonding (PTFE-to-PTFE)

• No adhesive required

• Bond strength > 2000 psi

• Void-free interfaces

• Superior electrical and mechanical integrity

• Thinner, lighter multilayer boards

Recommended for high-performance RF and aerospace designs.

Adhesive Bonding

Compatible bonding materials include:

• Rogers RO3000 / RO4000 series prepregs

• Thermoset polyimide films

• Epoxy-based bonding layers (e.g., FR-4 hybrid stacks)

Used for:

• Mixed dielectric stack-ups

• Metal-backed or heat-sink PCBs

• Complex multilayer structures

KKPCB supports both bonding methods depending on performance and cost requirements.

6. Typical Applications of RT/duroid 5880 PCBs

• Radar Systems – antennas, phased arrays, RF modules

• Aerospace & Defense – satellites, avionics, flight systems

• 5G & Wireless Infrastructure – base stations, test equipment

• Automotive Radar – ADAS, collision avoidance systems

• High-Speed Digital (20+ Gbps) – SERDES, backplanes

• Medical RF Devices – MRI coils, RF ablation systems

7. RT/duroid 5880 vs Other RF PCB Materials

RT/duroid 5880 remains the gold standard for ultra-low-loss RF circuits.

8. Design Guidelines for RT/duroid 5880 PCBs

Stack-Up Design

• Use symmetrical layer structures

• Balance copper distribution to minimize warpage

• Follow Rogers lamination guidelines

Trace Width & Spacing

• Minimum spacing ≥ 3× dielectric thickness

• Wider traces for higher current and reduced loss

Impedance Control

• Expect ±8% manufacturing tolerance

• Use field solvers with Rogers material models

Signal & Power Integrity

• Isolate RF from noisy digital circuits

• Use solid reference planes and proper decoupling

Thermal Management

• Use thermal vias under power devices

• Ensure airflow and copper heat spreading

Manufacturing Considerations

• Clearly define drilling, milling, and lamination cycles

• Use Rogers-qualified PCB manufacturers like KKPCB

9. Rogers RT/duroid 5880 – FAQ

Q1: Can RT/duroid 5880 be used for multilayer PCBs?

Yes. Both fusion bonding and adhesive bonding are supported, depending on performance requirements.

Q2: Is RT/duroid 5880 an RF material?

Yes. It is specifically designed for RF, microwave, and millimeter-wave applications.

Q3: Is RT/duroid 5880 suitable for flexible PCBs?

No. It is rigid. For RF flex PCBs, Rogers FlexWave materials are recommended.

Q4: Is RT/duroid 5880 suitable for aerospace use?

Yes. It meets aerospace-grade requirements including low outgassing and thermal stability.

Q5: RT/duroid 5880 vs FR-4?

Pros:

• Much lower loss

• Stable impedance

• Better thermal and moisture resistance

Cons:

• Significantly higher cost

• Specialized processing required

Rogers RT/duroid 5880 delivers unmatched electrical stability and ultra-low loss for mission-critical RF and microwave PCBs. While more expensive than FR-4, it is the preferred choice for applications where performance, reliability, and signal integrity cannot be compromised.

KKPCB specializes in Rogers PCB fabrication, offering:

• RT/duroid 5880 prototypes & mass production

• Hybrid Rogers + FR-4 stack-ups

• Controlled impedance RF PCBs

• Aerospace & automotive-grade manufacturing