PCB boards for electric vehicle (EV) controllers serve as the “brain” of EV powertrains, processing sensor data and controlling motor operation, battery energy distribution, and vehicle dynamics—critical for optimizing performance, efficiency, and safety. These PCBs are designed to handle complex signal processing and high-power output, requiring a balance of analog (for sensor signals), digital (for microprocessors), and power circuits on a single board.

Core components on these PCBs include: a main microcontroller (MCU, e.g., Infineon AURIX or Texas Instruments TMS570) for data processing, motor driver circuits (with MOSFETs or IGBTs to amplify control signals to the motor), and a battery management system (BMS) interface to monitor battery state of charge (SoC) and temperature. To support high-speed data transmission (for real-time motor control), PCBs use high-speed signal traces (impedance-matched to 50Ω or 100Ω) and multi-layer designs (8–16 layers) to separate analog/digital/power circuits, reducing interference.

Thermal management is critical: PCBs use thermal vias to transfer heat from power components to heat sinks, and may integrate metal core PCBs (MCPCBs) for high-power drivers. Safety features include overcurrent protection (via fuses or current sensors) and fault detection circuits that shut down the controller in case of anomalies. These PCBs are used in battery electric vehicles (BEVs) and hybrid electric vehicles (HEVs), from compact cars to commercial trucks. For EV manufacturers, reliable controller PCBs ensure smooth acceleration, regenerative braking, and extended battery life—key factors in user experience and vehicle competitiveness.