2025 Rogers RFPCB Materials Guide: R4350B vs. R4003 vs. R5880 – How to Choose for High-Frequency Designs

In the world of high-frequency electronics—where 5G networks, radar systems, and automotive ADAS (Advanced Driver-Assistance Systems) demand pixel-perfect signal integrity—Rogers Corporation’s RFPCB materials stand as the gold standard. Unlike generic FR4 PCBs, which struggle with signal loss and unstable dielectric properties above 1 GHz, Rogers materials (R4350B, R4003, R5880) are engineered to deliver consistent performance at frequencies up to 100 GHz. According to Grand View Research, the global RFPCB market is projected to grow at a CAGR of 8.5% from 2025 to 2032, driven by 5G expansion and aerospace/defense innovation—and Rogers materials capture over 35% of this high-performance segment.

This guide breaks down the critical properties of Rogers R4350B, R4003, and R5880, explains how they elevate RFPCB performance, and maps their applications across telecom, aerospace, and automotive industries. We’ll also help you choose the right Rogers material for your project and highlight what to look for in a manufacturing partner.

Key Takeaways
  1.Dielectric stability is non-negotiable: Rogers R4350B (Dk=3.48), R4003 (Dk=3.55), and R5880 (Dk=2.20) maintain consistent dielectric constants across frequencies/temperatures—critical for impedance control in 5G and radar.
  2.Low loss = better performance: R5880 leads with a loss tangent of 0.0009 (10 GHz), ideal for millimeter-wave systems; R4350B (Df=0.0037) balances performance and cost for mid-range RF applications.
  3.Industry-specific strengths: R5880 excels in aerospace (lightweight, -50°C to +250°C tolerance); R4003 fits automotive budgets; R4350B is the workhorse for 5G base stations.
  4.Rogers outperforms FR4: Rogers materials offer 50–70% lower signal loss and 3x better impedance stability than FR4, making them mandatory for high-frequency designs.
  5.Partner with experts: Manufacturers like LT CIRCUIT ensure Rogers materials are processed correctly (e.g., controlled lamination, precise drilling) to unlock their full potential.

Critical Properties of Rogers R4350B, R4003, and R5880
Rogers’ RFPCB materials are distinguished by three core traits: stable dielectric properties, ultra-low signal loss, and rugged environmental resilience. Below is a detailed breakdown of each material’s key specs and use cases.

1. Rogers R4350B: The Mid-Range RF Workhorse
R4350B is the most versatile Rogers material, balancing performance, cost, and manufacturability. It’s designed for mid-to-high frequency applications (8–40 GHz) where signal integrity and thermal management matter—but budget is still a consideration.

Key Specifications of R4350B

Ideal Applications for R4350B
  a.5G macro base station antennas and small cells
  b.Microwave point-to-point (P2P) communication links
  c.Automotive radar sensors (short-range, 24 GHz)
  d.Industrial RF sensors (e.g., level detectors, motion sensors)

Example: A leading telecom manufacturer used R4350B for 5G small cell antennas, reducing signal loss by 30% compared to FR4. This improved coverage by 15% in urban areas.

2. Rogers R4003: The Budget-Friendly RF Solution
R4003 is Rogers’ entry-level RF material, designed for cost-sensitive applications that still require better performance than FR4. It’s compatible with standard PCB manufacturing processes (no special tools needed), making it ideal for high-volume production.

Key Specifications of R4003

Ideal Applications for R4003
  a.Automotive V2X (Vehicle-to-Everything) communication modules (5.9 GHz)
  b.Wi-Fi 6/6E routers and access points
  c.Low-power RF transceivers (e.g., IoT sensors)
  d.Consumer RF devices (e.g., wireless charging pads with RF feedback)

Example: A major automaker adopted R4003 for V2X modules, cutting material costs by 25% vs. R4350B while maintaining signal reliability in urban traffic environments.

3. Rogers R5880: The High-Performance Millimeter-Wave Leader
R5880 is Rogers’ premium material for ultra-high-frequency applications (24–100 GHz). Its ultra-low loss and exceptional thermal stability make it the top choice for aerospace, defense, and advanced 5G (mmWave) designs.

Key Specifications of R5880

Ideal Applications for R5880
  a.5G mmWave base stations and user equipment (e.g., smartphones with mmWave)
  b.Aerospace radar systems (e.g., airborne early warning radar, 77 GHz)
  c.Satellite communication payloads (Ka-band, 26–40 GHz)
  d.Defense electronic warfare (EW) systems

Example: A defense contractor used R5880 for a 77 GHz airborne radar, achieving a 40% reduction in signal loss compared to R4350B—extending the radar’s detection range by 20 km.

Side-by-Side Material Comparison
To simplify selection, here’s how R4350B, R4003, and R5880 stack up against each other and FR4 (the most common generic PCB material):

How Rogers Materials Elevate RFPCB Performance
Rogers materials don’t just “work” for RFPCBs—they solve the core pain points that generic materials (like FR4) can’t. Below are three key performance advantages that make Rogers indispensable for high-frequency designs.

1. Impedance Control: The Foundation of Signal Integrity
Impedance control (matching the PCB’s electrical resistance to the component’s needs, e.g., 50Ω for RF antennas) is critical for minimizing signal reflection and loss. Rogers materials excel here thanks to their stable dielectric constants.

Why Rogers Beats FR4 for Impedance Control

Real-World Impact: A 5G mmWave antenna using R5880 maintained 50Ω impedance with ±1% tolerance across its entire surface. The same design with FR4 had impedance variations of ±7%, leading to 15% signal loss at the antenna edges.

2. Ultra-Low Signal Loss for High-Frequency Designs
At frequencies above 1 GHz, signal loss (from dielectric absorption and conductor resistance) becomes a major issue. Rogers materials minimize this loss, enabling longer signal ranges and clearer data transmission.

Signal Loss Comparison (10 GHz)

Key Insight: For 5G mmWave (28 GHz), signal loss doubles every 100 meters. Using R5880 instead of FR4 extends the maximum usable range of a mmWave base station from 200m to 400m—critical for urban 5G coverage.

3. Environmental Resilience: Ruggedness for Harsh Conditions
RFPCBs often operate in tough environments: outdoor 5G enclosures (rain, temperature swings), automotive engine bays (heat, vibration), and aerospace systems (extreme cold, radiation). Rogers materials are engineered to survive these conditions.

Environmental Performance Comparison

Example: A military radar system using R5880 operated reliably in the Arctic (-50°C) and desert (+50°C) environments for 5 years. The same design with FR4 required quarterly maintenance due to delamination and signal drift.

Rogers Material Applications Across Key Industries
Rogers R4350B, R4003, and R5880 are tailored to the unique needs of three high-growth industries: telecommunications, aerospace/defense, and automotive. Below is how each material fits into these sectors.

1. Telecommunications: Powering 5G and Beyond
The global 5G rollout is the single biggest driver of Rogers RFPCB demand. 5G requires materials that handle both sub-6 GHz (wide coverage) and mmWave (high speed) frequencies—something FR4 can’t do.

Market Data: Rogers estimates that 5G base stations use 2–3x more RFPCB material per unit than 4G stations—and 80% of these use R4350B or R5880.

2. Aerospace & Defense: Ruggedness for Critical Missions
Aerospace and defense applications demand materials that perform flawlessly in extreme conditions: zero gravity, radiation, and temperature swings from -50°C to +250°C. Rogers materials meet these standards.

Case Study: A leading aerospace company used R5880 for a satellite’s Ka-band payload. The material maintained stable Dk (±0.01) in space for 10 years, ensuring uninterrupted communication between the satellite and ground stations.

3. Automotive: Safety and Connectivity for Smart Cars
Modern cars rely on RF technology for safety (ADAS radar), connectivity (V2X), and infotainment (Wi-Fi/Bluetooth). Rogers materials are designed to withstand automotive-specific challenges: heat, vibration, and harsh chemicals.

Trend: By 2027, 90% of new cars will include ADAS radar—most using Rogers R4350B or R5880. This is because FR4-based radar sensors fail 3x more often in extreme heat than Rogers-based ones.

How to Choose the Right Rogers Material for Your RFPCB
Selecting the correct Rogers material depends on three factors: frequency, environment, and budget. Use this step-by-step framework to make the right choice.

Step 1: Match Material to Frequency
The first rule of RFPCB design is: higher frequency = lower Dk and Df. Use this guide to align material with your project’s frequency range:

Step 2: Consider the Operating Environment
 1.Environmental conditions (temperature, humidity, vibration) narrow down your options:
 2.Extreme temperatures (-50°C to +250°C): Choose R5880 (aerospace, defense).
 3.Moderate temperatures (-40°C to +150°C): Choose R4350B (5G base stations, automotive engine bays).
 4.Mild temperatures (-40°C to +125°C): Choose R4003 (consumer electronics, in-cabin automotive).
 5.High humidity/vibration: All Rogers materials work, but R5880 offers the best resistance to delamination.

Step 3: Balance Performance and Budget
Rogers materials cost more than FR4, but the investment pays off in reliability. Use this budget guide:
 1.Premium performance (no cost limits): R5880 (aerospace, mmWave 5G).
 2.Balanced performance/cost: R4350B (5G base stations, mid-range radar).
 3.Budget-sensitive (high volume): R4003 (V2X, Wi-Fi 6 routers).

Example Decision Tree:
If you’re designing a 24 GHz ADAS radar for a mainstream car:
 1.Frequency = 24 GHz → R4350B or R5880.
 2.Environment = engine bay (+150°C) → Both work.
 3.Budget = mainstream car → R4350B (30% cheaper than R5880).

Why Partner with LT CIRCUIT for Rogers RFPCBs
Even the best Rogers material will underperform if not manufactured correctly. LT CIRCUIT specializes in processing Rogers R4350B, R4003, and R5880, with the expertise to unlock their full potential.

1. Advanced Manufacturing Capabilities
LT CIRCUIT uses specialized equipment and processes to handle Rogers’ unique properties (e.g., low Dk, high Tg):
  a.Controlled Lamination: Uses vacuum hot presses (temperature ±2°C, pressure ±1 kg/cm²) to ensure uniform bonding—critical for maintaining Dk stability.
  b.Precision Drilling: Laser drills (10μm accuracy) create microvias for dense RF designs; mechanical drills with diamond bits prevent material fraying.
  c.Plating: Electroless copper plating (0.5μm thickness) ensures uniform coverage in microvias, reducing signal loss.
  d.Testing: In-line AOI (5μm resolution) and X-ray inspection (20μm resolution) catch defects like voids in vias or uneven trace widths.

2. Industry Certifications and Quality Control
LT CIRCUIT meets the strictest standards for RFPCB manufacturing, ensuring consistency and reliability:

3. Custom Solutions for Complex RF Designs
LT CIRCUIT works closely with clients to tailor Rogers RFPCBs to their specific needs:
  a.Custom Stackups: Designs multi-layer RFPCBs (up to 12 layers) with Rogers materials for complex impedance profiles (e.g., differential pairs for mmWave).
  b.Material Combinations: Combines Rogers with FR4 in hybrid PCBs (Rogers for RF sections, FR4 for power sections) to reduce costs.
  c.Prototype to Production: Offers fast prototyping (2–3 days for R4350B) and high-volume production (100k+ units/month) with consistent quality.

Case Study: LT CIRCUIT helped a 5G equipment maker design a hybrid RFPCB: R5880 for the mmWave antenna section and FR4 for the power management section. This reduced material costs by 20% while maintaining signal integrity.

FAQ: Common Questions About Rogers RFPCBs
1. Can Rogers materials be used in multi-layer RFPCBs?
Yes—Rogers R4350B, R4003, and R5880 are all compatible with multi-layer designs (up to 12 layers). Key considerations include:
  a.Using symmetric stackups to prevent warping (e.g., R4350B layers on top/bottom, FR4 inner layers for cost).
  b.Ensuring uniform lamination pressure to maintain Dk stability across layers.
  c.Using blind/buried vias (laser-drilled) to avoid signal loss through the entire board.

2. Are Rogers RFPCBs compatible with standard PCB assembly processes?
Mostly—R4003 and R4350B work with standard reflow soldering (peak temp 260°C) and SMT placement. R5880 requires slightly modified processes:
  a.Lower reflow peak temp (240°C) to avoid damaging the low-Dk material.
  b.No cleaning with aggressive solvents (use isopropyl alcohol) to prevent material degradation.

3. How do I test the performance of a Rogers RFPCB?
Critical tests for Rogers RFPCBs include:
  a.Impedance testing: Use a TDR (Time Domain Reflectometer) to verify impedance tolerance (±1% for R5880, ±2% for R4350B/R4003).
  b.Insertion loss testing: Use a VNA (Vector Network Analyzer) to measure signal loss across your frequency range.
  c.Thermal testing: Use an infrared camera to check heat dissipation from high-power components.
  d.Environmental testing: Conduct thermal shock and humidity tests to validate long-term reliability.

4. Is it possible to reduce costs with Rogers materials?
Yes—try these strategies:
  a.Use hybrid PCBs (Rogers for RF sections, FR4 for non-RF sections) to cut material costs by 20–30%.
  b.Choose R4003 for low-to-mid frequency designs instead of R4350B.
  c.Work with a manufacturer like LT CIRCUIT to optimize panel size (maximize number of PCBs per panel).

Conclusion: Rogers Materials Are the Future of High-Frequency RFPCBs
As electronics push toward higher frequencies (5G mmWave, 6G, advanced radar), the limitations of generic materials like FR4 become impossible to ignore. Rogers R4350B, R4003, and R5880 solve these limitations with stable dielectric properties, ultra-low signal loss, and rugged environmental resilience—making them the only choice for critical RF designs.

To recap:
  a.R5880 is the premium choice for mmWave and aerospace/defense, where performance is non-negotiable.
  b.R4350B is the versatile workhorse for 5G and mid-range radar, balancing performance and cost.
  c.R4003 is the budget-friendly option for high-volume, low-to-mid frequency designs like V2X and Wi-Fi 6.

The key to success with Rogers materials is partnering with a manufacturer that understands their unique processing needs—like LT CIRCUIT. With specialized equipment, strict quality control, and custom design support, LT CIRCUIT ensures your Rogers RFPCB delivers the performance you need.

Looking ahead, Rogers materials will play an even bigger role in 6G (100–300 GHz), autonomous vehicles (multi-frequency radar), and space exploration (radiation-hardened designs). By choosing the right Rogers material and manufacturing partner today, you’ll be ready to lead in the next era of high-frequency electronics.