What are possible solutions to PCB warpage problems?

My PCB manufacturer just informed me that he is facing PCB warpage issue in my simple, single sided, copper poured PCB. He says to avoid this issue he suggests to add a dummy copper patch by keeping 3mm copper clearance from all sides. Can somebody tell me what leads to this issue and what are possible solutions to this problem ?

November 10, 2023

The problem you mentioned is due to an imbalance in thermal expansion/shrink between layers (in this case copper vs base material, like laminate). When the copper from one side of PCB is completely etched it tends to warp when the copper on the other side cools. It happens when there is the non-even number of layers.

Solution:

Use double-sided PCB (or any even number of layers)
Instead of solid copper, try to use grid copper, which is named “hatch” in the PCB CAD program.

#PCB Manufacturing

Oliver Smith

Oliver is an experienced electronics engineer skilled in PCB design, analog circuits, embedded systems, and prototyping. His deep knowledge spans schematic capture, firmware coding, simulation, layout, testing, and troubleshooting. Oliver excels at taking projects from concept to mass production using his electrical design talents and mechanical aptitude.

Oliver Smith

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