This paper explores the design challenges and technological considerations involved in developing PCB-based power modules for high-performance applications, specifically within off-highway vehicles. As power electronics evolve, integrating control and power systems into compact, thermally managed PCBs becomes increasingly critical. Using a 40 kVA off-road vehicle application as a reference, the study examines key aspects of PCB design, including: Contact technologies (solder, press-fit, spring contacts), impact on reliability, serviceability, sustainability. Electrical design constraints, such as current paths up to 50 A and voltages reaching 700 V. Creepage and clearance distances, e.g. under high-altitude operating conditions. Layer stack-up configurations, including copper thickness, wire mesh integration & insulation. Self-heating behavior across different design variants, validated through simulation and thermographie.
