Rogers vs PTFE vs Teflon: Choosing the Best PCB Laminate for High-Frequency Design

FR4, being the most popular one, is not always used in high-frequency PCBs because this PCB laminate can degrade the signal performance at high frequencies. Not because they consist of any wrong conduction material, but the reality lies in the substrate dielectric properties. The dielectric itself attenuates the signal at high frequency. So, after a lot of research in this area, we got some really good materials. The three alternatives for high-performance PCBs are Rogers, PTFE, and Teflon laminates. They offer better dielectric control, lower signal loss, and superior thermal stability. But they differ a lot from the cost perspective from standard FR4. In this guide, we will get through:

• Basics of Rogers, PTFE, and Teflon laminates.

• Compare their dielectric constants, losses, and thermal performance

• Provide a detailed design example showing how material choice impacts a PCB trace for RF use.

Why Material Choice Matters in PCB Design

Two key electrical properties of a laminate define how it will behave in high-frequency circuits:

1. Dielectric Constant (Dk or εr):

It determines the speed of signal propagation. Lower the value of Dk means faster signal speed, longer wavelength. The dielectric constant of a material also affects impedance calculation for traces. Rogers typically offers Dk = 2.2–6.5, PTFE/Teflon often ~2.1.

2. Loss Tangent (Df or tan δ):

It represents dielectric losses (how much RF energy is lost as heat). Lower loss tangent means higher efficiency. A table below is given for all FR4, Roger, and PTFE for comparison:

●       FR-4: ~0.015–0.02 at 1 GHz

●       Rogers RO4350B: ~0.0037

●       PTFE/Teflon: ~0.0002–0.0009  

Understanding the Materials

1.  Rogers Laminates:

Rogers Corporation produces a wide range of high-frequency PCB laminates (e.g., RO4000, RO3000 series). The composition includes hydrocarbon-ceramic or PTFE composites.
Because of the laminate properties, it is excellent from hundreds of MHz into tens of GHz due to low losses. Rogers has better stability to heat than any other high-frequency material. They are particularly used in radar, satellite, and precision RF technologies.

2. PTFE (Polytetrafluoroethylene) Laminates

It is a type of polymer with an extremely low dielectric constant variation over frequency. It has the lowest losses among all but is more affected by heat. It has very good electrical signal handling properties, but is mechanically very soft in nature, because of which the copper layer may expand or contract as per temperature. It is commonly used in medical and radar applications.

3. Teflon Laminates

Teflon is a brand name for PTFE (registered by DuPont/Chemours). In PCB terminology, "Teflon boards" are usually PTFE-based PCBs. Same low-loss, low-Dk characteristics as PTFE, but “Teflon” often refers to pure PTFE or PTFE composites. They need special manufacturing processes due to their softness. And commonly used in very high-frequency microwave boards (>10 GHz), aerospace communication.

Practical Impact: Transmission Line Example

Let’s take a real-world example: Designing a 50 Ω microstrip trace at 10 GHz. Let the thickness of the PCB be 0.8mm and the copper thickness if 35 μm. We’ll calculate the trace width required for 50 Ω impedance.

1. Case A: Rogers RO4350B

Dk = 3.48, Df = 0.0037, Using microstrip impedance formulas:

●       Required width ≈ 1.6 mm

●       Attenuation ≈ 0.26 dB/inch  

2. Case B: PTFE/Teflon

Dk = 2.1, Df = 0.0005, Using microstrip impedance formulas:

●       Required width ≈ 2.45 mm

●       Attenuation ≈ 0.04 dB/inch  

3. Case C: FR-4 (for comparison)

Dk ≈ 4.4, Df ≈ 0.017, Using microstrip impedance formulas:

●       Required width ≈ 1.35 mm

●       Attenuation ≈ 0.82 dB/inch (significant signal loss at 10 GHz)  

Lower Dk means wider traces for the same impedance. This can impact board real estate. PTFE/Teflon drastically outperforms FR-4 and even Rogers for ultra-high frequency due to extremely low loss tangent. Rogers is easier to process than pure PTFE/Teflon.  

Choosing the Right Material

When to Choose Rogers:

●       Mid- to high-frequency designs up to ~20 GHz.

●       Need a balance of performance and manufacturability.

●       Mixed-signal boards with both RF and digital sections.  

When to Choose PTFE/Teflon:

●       Ultra-low loss needed (radar, satellite comms).

●       Frequencies >20 GHz.

●       High reliability in extreme conditions (space).  

Conclusion:

The decision between Rogers, PTFE, and Teflon comes down to:

●       Frequency and loss budget

●       Manufacturing capability

●       Budget

●       Mechanical constraints

All these are discussed in a very detailed format in this blog. For many RF designers, Rogers RO4350B is the “sweet spot” for up to 20 GHz. For bleeding-edge, ultra-low-loss systems, PTFE/Teflon remains unmatched. With high-frequency material, we will always encounter some fabrication challenges.