Plugged Vias | Uses, Description, and Application


Manufacturers use plugged vias in the manufacturing of printed circuit boards. They connect different layers of the board, allowing electricity to flow through them. Plugged Vias are also useful in holding components in place during the soldering process.

Plugged Vias Uses, Description, and Application

Plugged Vias is a type of via filled with a conductive material. The purpose of plugged vias is to improve the electrical properties of the circuit board, as well as reduce signal loss.

Copper and silver alloys are used to make plugs, which can be used to connect one layer of the board to another. Some plugged vias are used for grounding purposes.

The main advantage of using plugged vias is that they can help reduce signal loss and improve electrical performance. They also provide better mechanical support than regular vias, making them ideal for high-frequency applications such as high-speed communications networks or computers with fast processors.

What is a Via?

A via is a type of connection used in electronics. A via is typically used to connect two layers of a circuit board that are otherwise not connected. The top layer is called the surface and the bottom layer is called the core.

Vias are holes drilled through both layers, connecting them. Vias are often used when there is no other way to connect two layers, as they allow for better heat transfer and signal transmission.

A via is a hole in a circuit board that allows you to attach wires or components to the board without having to solder them directly. The holes are usually filled with conductive material, making them more durable than a normal hole.

Plugged Vias Description

When you’re working on a circuit board and creating a via (a hole in the board), there are a few different options for filling it with resin. The first option is to leave the via empty and let air flow through it, which can cause problems with signal transmission. The second option is to plug the via with solder, which can be messy and time-consuming. The third option is to plug the via with resin, which we call “plugged vias.”

Plugged Vias in electronics is a way of dealing with the problem of having a connection between two parts of your circuit, which is unnecessary. If your circuit has a part that you don’t need and doesn’t need to access, then you must still connect it to another part of your circuit. In this case, you can use a plugged via to connect those two parts.

This is done to provide an electrical connection. The connection between the top and bottom of a board ensures that the board remains solid. The vias are drilled, filled with resin or solder mask, and then sanded to remove excess material.

Types of Plugged Vias

What are plugged vias? This concept could be clearer for some people, especially when placed in the context of circuit boards. Here we’ll try to explain what plugged vias are, their types, and provide some advantages and disadvantages.

Non-Conductive Plugged Via

Non-Conductive Plugged Via

Non-Conductive Plugged Via

Can be used to electrically isolate one or more conductive layers from each other and the outside world. A via hole is produced in a via layer, which may be part of a multilayer laminate or in a substrate layer.

The barrel is filled with non-conductive material like epoxy resin. This method can also be used to protect copper pads on PCBs or components against corrosion caused by electrolytes.


An option is to make sure they’re not allowing any conductivity through their circuit board. It’s especially useful when the circuit board is being used in high-voltage applications, or other factors could cause the circuit board to become hot enough to melt and damage itself.

Non-Conductive Plugged Via also helps prevent damage to the hardware itself. For example, if an external source were overheating your circuit board, this would be able to help prevent it from being damaged.


Non-conductive plugged vias can complicate the assembly of full-thickness boards. If you have non-conductive plugged-via parts, make sure to set your tools up to cut them on a single pass. If you are going for aesthetics, the old triangle cut or chamfer may be better options since these approaches leave a smooth edge around the via.

Conductive Plugged Via

Conductive Plugged Via

Conductive Plugged Via

These vias are a type of via that connects two different layers in a PCB. They are used in high-reliability applications where the PCB needs to be connected to another layer without compromising its integrity.

A conductive plugged via has an additional component: a plug on the bottom side of the PCB. This plug ensures no movement between layers and prevents them from separating. The plug can be made from solder or epoxy material.


One of the biggest benefits is that a conductive plugged via is more effective at transferring thermal energy than a non-conductive plugged via. This means that the thermal energy in the metal will be transferred to the other material more quickly, and therefore you will have a better heat transfer rate.


Although conductive plugged vias can be a great alternative, they have some disadvantages. If your product is going to be subjected to high temperatures or extreme humidity, you may want to consider a non-conductive plugged via.

Conductive plugged vias do not provide a CTE match with the laminate material. This means that even if you use conductive material in your vias and then thermally bond the laminate, there will still be strain between the two materials as they expand and contract at different rates over time.

Covered Plugged Via

Covered Plugged Via

Covered Plugged Via

These vias are a great way to protect your circuit board from damage and improve its electrical properties. They are also a great option if you want to hide the holes in your circuit board.

This type of via is plugged with solder mask or some other non-conductive media and covered by the solder mask or other chemical materials. This can be done using a laser, hot wire, or mechanical means. The process of covering the hole with soldermask and then covering it again with another layer of soldermask yields a highly reliable connection that is nearly impossible to break without damaging the circuit board itself.


Covered plugged vias are an innovative new way to protect your circuit boards. The solder mask is a layer of resin that covers the holes in your circuit board and protects the copper from oxidation and corrosion. With covered plugged vias, you can also protect your circuit boards from damage caused by high temperatures.


This via comes with a cover over the hole, which protects it from damage. It also makes the via more secure and less likely to come loose.

This is a great option for something that’s durable and long-lasting. However, one thing you should be aware of is that covered plugged vias can be more expensive than other types of vias.

When Do You Use Plugged Vias?

Plugging is a useful option for PCB designs that has an electronic component that needs to be cooled, then you will want to use conductive via plugging to help transfer heat away from the component and into your circuit board.

For example, you may have a power supply on one side of your PCB and an LED array on the other. You could use conductive via plugging to connect these two components. You can connect these components without having to run wires from one side of the board to another. This would allow you to keep your PCB design clean and simple while still ensuring that there is a good electrical connection between components that require it.

Also, another usage is the flow of solder material during the assembly/soldering process can be prevented by plugged vias. These are small metal plugs that fit inside conductive vias in electronic assemblies. They act as a barrier to prevent the flow of solder material. Securing the vias from unwanted solder flow during the assembly/soldering process.

Advantages of Plugged Vias

Plugged Vias Advantages

Advantages of Plugged Vias

There are many advantages to using plugged vias. These are the following:

Plugged Vias Prevents Solder from Entering the Via

Soldering is a common method of connecting electronic components, but it can be messy. If solder is allowed to enter into the via, it may cause a short circuit between active pads or other problems with the circuit. A plated via prevents this from happening by preventing contaminants from entering into the via.

Plugged Vias Offers Active Pads Strength and Structural Support

Active pads have an electrical connection to another part of the circuit by way of a trace or wire. Without support from a plated via, these active pads can become loose over time and cause connectivity issues or malfunction altogether. Plating provides strength and structural support so these parts stay in place over time.

Plugged Vias Improve Pad and Via Stability and Reliability

A plated via improves stability and reliability by providing more contact area for solder paste during soldering. This helps prevent shorts in your circuit due to insufficient bonding between pad and trace (the metal wire connecting two points). This also helps reduce thermal stress on components due to heat dissipation from the soldering process.

Disadvantages of Plugged Vias

Plugged Vias Disadvantages

Disadvantages of Plugged Vias

These kinds of vias also have a few disadvantages. Here are a few of them:

Copper Pad and Copper Plating Instability

The biggest disadvantage of plugged vias is probably the instability of the copper pad and copper plating inside the via hole barrel. This can make it difficult to use a standard reflow process, and you must do extra work with your board after you’ve assembled it.

Low Thermal Conductivity Versus Electroplated Copper

Another disadvantage is that because these vias are filled with conductive epoxy, they don’t have as high thermal conductivity as electroplated copper. So if you’re using them in an application where heat dissipation is important, this may be something you want to look into further before deciding on a plugged-via solution.

IPC-4761 Via Plugging Guidelines

IPC-4761 Guidelines

IPC-4761: Via Plugging Guidelines

These Via Plugging Guidelines aims to standardize the following:

Maintain the Vacuum During the In-Circuit Test

The manufacturer should be responsible for maintaining the vacuum during the in-circuit test, which means ensuring that there’s no air getting into or out of the system. This is especially important because air inside the system can ruin our results, which are critical for quality assurance.

Closure of the Via Against Penetration of Media into the Via

The via should be closed against media penetration into the via on one side. This is accomplished by placing a conductive material between opposing pads, which allows for electrical connections through the layers of the package substrate and between conducting layers within the same layer.

Electrical Protection of the Via Annular Ring

The via annular ring is metal, forming a barrier between the top and bottom of a via. It has an opening in a printed circuit board (PCB). The manufacturer should provide electrical protection via an annular ring on one side.

Improvement of the Soldering Result Due to Non-Solderable Vias

The soldering result is an important process in manufacturing electronic components, especially in manufacturing Plugged Vias. It is necessary to ensure that the soldering result is consistent and reliable. We ensure the high quality of our products.

PCBTok Plugged Via Manufacturer

PCBTok Plugged Via Manufacturer

Why Choose PCBTok as your Plugged Via Manufacturer?

PCBTok is the world’s leading manufacturer of plugged via, and we can help you achieve your goals. We have over a decade of experience in the field, and our team comprises skilled engineers and technicians who are passionate about what they do.

Our company has grown to be one of the most reliable manufacturers in Asia. Our goal is to provide our customers with the highest quality products at an affordable price, so everyone can benefit from our services.

We are always looking for ways to improve our business model and our products and services. We hope to continue providing excellent service to our customers every day.


I hope you got a better understanding of plugged vias, their general use, and their limitations. In general, vias are the small holes in a printed circuit board that connect copper foil layers. Some vias have large holes that allow for the use of conductive epoxy to provide an electrical connection. Vias of this type usually are covered by a solder mask when populated with components. Plugged vias are filled with resin or sometimes solidified with heat leaving a fill in the hole. These are is painted over leaving only the desired circuitry exposed.

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