Arlon AD vs DiClad: understand the real differences between ceramic-filled PTFE and pure fiberglass/PTFE laminates. Full comparison of electrical properties, CTE, PIM, and which series fits your application.

Picking the wrong laminate family for a high-frequency design is one of those mistakes that doesn’t always show up immediately. The board passes initial impedance testing, looks fine on the bench, and then degrades in the field over thermal cycling or starts causing PIM issues in a multi-carrier base station. When engineers ask “what’s the difference between the Arlon AD Series and the DiClad Series,” they’re usually asking because they’ve hit exactly this kind of wall.

This guide breaks down the Arlon AD vs DiClad comparison in practical terms — construction chemistry, electrical performance, processability, and which family actually makes sense for which type of design. Both series share PTFE-based roots, but the engineering decisions made in each are quite different, and those decisions have real consequences at the board level.

Understanding the Arlon Microwave Materials Lineage

Before diving into the comparison, it helps to understand where these materials sit in the broader Arlon ecosystem. Arlon Electronic Materials Division — now operating under Rogers Corporation following their acquisition — has over 50 years of experience in PTFE-based microwave laminates. The division is a major manufacturer of specialty high-performance laminate and prepreg materials, with applications spanning avionics, semiconductor testing, heat sink bonding, high-density interconnect, and microwave PCBs for mobile communication products.

Within Arlon’s microwave materials catalog, both the AD Series and DiClad Series are PTFE-based woven fiberglass composites, but they diverge significantly in construction. The AD Series introduces ceramic fillers into the matrix — which changes the performance profile substantially. The DiClad Series sticks to a purer fiberglass/PTFE composite without ceramic reinforcement. Understanding why that matters starts with the materials science.

What Is the Arlon DiClad Series?

DiClad Construction: Woven Fiberglass and PTFE

Rogers DiClad Series laminates are fiberglass-reinforced PTFE-based composites for use as printed circuit board substrates in high-frequency applications. The controlled fiberglass and PTFE content ratio enables DiClad laminates to offer a range of low dielectric constant (Dk) values. Higher PTFE content provides a lower Dk and loss tangent, while higher fiberglass content provides better dimensional stability and registration.

Unlike the CuClad laminate series, the DiClad laminates do not have cross-plied constructions. This is an important fabrication note: the fiberglass plies in DiClad materials are aligned in the same direction, which means the material behaves differently in X vs. Y from an expansion standpoint compared to the cross-plied CuClad alternatives.

DiClad Grades: 527, 870, and 880

The DiClad family covers three main substrate grades, each tuned to a different fiberglass/PTFE ratio:

DiClad 522 and DiClad 527 use a higher fiberglass/PTFE ratio to provide mechanical properties approaching conventional substrates. Other advantages include better dimensional stability and lower thermal expansion in all directions.

DiClad 870 uses a medium fiberglass/PTFE ratio for lower dielectric constant and improved dissipation factor without sacrificing mechanical properties. DiClad 880 uses a low fiberglass/PTFE ratio to provide the lowest dielectric constant in the series — Dk of 2.17 or 2.20 — with a correspondingly excellent dissipation factor of 0.0009 at 10 GHz.

DiClad laminates are frequently used in filter, coupler, and low noise amplifier applications where dielectric constant uniformity is critical. They are also used in power dividers and combiners where low loss is important.

DiClad Electrical Properties at a Glance

Grade	Dk (10 GHz)	Df (10 GHz)	Fiberglass/PTFE Ratio	Key Strength
DiClad 527	2.40–2.65	0.0017	High	Dimensional stability, mechanical toughness
DiClad 870	2.33	0.0013	Medium	Balanced Dk and Df
DiClad 880	2.17, 2.20	0.0009	Low	Lowest loss, lowest Dk in series

These numbers come directly from the Rogers/Arlon datasheet (IPC-TM-650 testing at 23°C, 50% RH). The DiClad 880’s Df of 0.0009 at 10 GHz represents one of the lowest loss values available in a woven fiberglass-reinforced PTFE laminate — which is why it earned its reputation in precision filters, couplers, and low-noise amplifier circuits.

What Is the Arlon AD Series?

AD Series Construction: The Three-Component Approach

This is where the Arlon AD vs DiClad comparison gets interesting. The AD Series doesn’t just use fiberglass and PTFE. The AD250C, AD255C, and AD260A microwave high-frequency PCB materials leverage a cost-efficient blend of composite chemistry and architecture, integrating the excellent thermal properties of fluoropolymer resin systems with carefully selected ceramic materials and glass fiber reinforcements.

The addition of micro-dispersed ceramic filler is the defining engineering decision that separates the AD Series from the DiClad family. Ceramics change the thermal behavior of the laminate in ways that pure fiberglass/PTFE composites cannot achieve. The addition of differential dispersion ceramics provides thermal stability in the form of lower CTE and higher temperature phase stability.

The Three Generations of AD Series Laminates

Understanding the suffix designations on AD Series products explains a lot about their evolution. According to Cirtech Electronics’ detailed product history, the first-generation AD Series products used the ‘L’ designation, built from PTFE and woven fiberglass for lower Dk options in the 2.50–3.50 range. The ‘A’ designation followed, introducing ceramic-filled layers to replace some unfilled resin layers — reducing cost, Z-axis expansion, and dissipation factor simultaneously. The ‘C’ designation represents the current third generation, pushing ceramic content further to reduce Z-axis expansion and Df even further while maintaining cost efficiency.

These advanced materials are distinguished by their low dielectric constants, cost-effectiveness, and exceptional low-loss characteristics, making them highly suitable for modern telecommunications infrastructure.

AD Series Grades

Grade	Dk (10 GHz)	Df (10 GHz)	Dk Tolerance	Primary Use
AD250C	2.50	0.0014	±0.04	Low-cost telecom antenna boards
AD255C	2.55	0.0013	±0.04	Base station antennas, 5G feeds
AD260A	2.60	0.0014	±0.04	Antenna arrays, commercial wireless
AD300C/D	3.00	~0.002	Controlled	Higher Dk antenna systems
AD350A	3.50	~0.003	Controlled	Compact antenna applications

The tightly controlled Dk tolerances (±0.04) across the series are critical for antenna manufacturing at volume. These AD Series materials ensure consistent antenna performance and reliable operation, with ultra-low PIM values as low as -165 dBc, ensuring minimal signal interference.

Arlon AD vs DiClad: Direct Comparison

Core Chemistry Differences

Property	DiClad Series	AD Series
Resin System	PTFE	PTFE + micro-dispersed ceramic
Reinforcement	Woven fiberglass only	Woven fiberglass + ceramic fillers
Construction	Single-direction ply alignment	Standard layup
Generations	Mature, stable product line	Three generations (L, A, C)
Cross-plied option	No (CuClad is the cross-plied variant)	No

Electrical Performance Comparison

The most significant electrical difference between the two series is the loss tangent floor and the dielectric constant range each covers.

DiClad 880, at Df = 0.0009 at 10 GHz, achieves the lowest loss of any material in either family. This is possible because of the high PTFE content in the 880 grade — PTFE itself has naturally very low loss, and maximizing its proportion in the matrix minimizes dielectric losses. The AD Series’ Df of 0.0013–0.0014 at 10 GHz is still excellent by any standard, but it doesn’t quite reach the floor that a low-fiberglass PTFE laminate like DiClad 880 can achieve.

On the other hand, the AD Series’ tighter Dk tolerance and better thermal Dk stability give it an advantage in broadband, temperature-varying applications. The ceramic fillers compensate for PTFE’s negative temperature coefficient of dielectric constant — meaning the AD Series’ Dk stays more stable across the operating temperature range than a pure fiberglass/PTFE composite.

Performance Factor	DiClad 880 Winner	AD255C Winner
Absolute lowest Df	✓	—
Dk stability over temperature	—	✓
PIM performance	Competitive	✓ (specified)
Dk range (low end)	✓ (2.17)	2.50 minimum
Cost efficiency at volume	—	✓
Phase stability across temperature	Good	Better

Dimensional Stability and CTE

This is one of the clearer advantages of the AD Series. The AD Series’ low Z-axis thermal expansion significantly improves the reliability of plated through-hole (PTH) connections compared to typical PTFE base materials. Additionally, low X-Y expansion enhances the reliability of BGA solder joints.

The ceramic fillers essentially act as a thermal expansion moderator. PTFE itself has a relatively high CTE, and when you’re running PTH barrel through many thermal cycles, that Z-axis expansion can fatigue the copper barrel plating. The AD Series’ ceramic loading brings the Z-CTE down toward copper’s expansion rate, reducing the mechanical stress at each thermal cycle. For DiClad materials, particularly the 880 grade with its high PTFE content, this trade-off is accepted in exchange for the superior low-loss electrical performance.

Passive Intermodulation (PIM) Performance

PIM performance is a distinguishing factor that almost never comes up when engineers are designing filters or couplers, but becomes absolutely central to antenna design. AD255C is the third-generation commercial microwave and RF laminate material designed with low dielectric, low cost and excellent low-loss characteristics, built on a cost-effective combination for CTE values and greater phase stability across temperatures.

The AD Series explicitly targets PIM-sensitive applications. Reverse-treated ED copper is recommended for reduced PIM performance, and some grades offer a “PIM+” performance option. The DiClad series, while a capable microwave laminate, was not specifically developed with PIM minimization as a primary design target — it was optimized for the filter, coupler, and LNA market where insertion loss and Dk uniformity dominate the design requirements.

Which Series for Which Application?

When to Choose Arlon DiClad

DiClad 880 is your material when you need the lowest possible insertion loss and your Dk requirement falls in the 2.17–2.20 range. Precision microwave filters, couplers, and power dividers benefit most from this material’s Df = 0.0009 performance. If you’re building a combiner network for a high-power radar or a low-noise downconverter where every tenth of a dB matters, DiClad 880 is hard to beat in the woven fiberglass PTFE category.

DiClad 527 is the workhorse for applications where you need mechanical robustness in a low-Dk PTFE-based material. Its higher fiberglass/PTFE ratio provides dimensional stability that makes fabrication more predictable — tighter tolerance on layer-to-layer registration in multilayer builds, better resistance to the creep and cold-flow behavior that can plague high-PTFE-content materials.

DiClad 527 is used in military radar feed networks, commercial phased array networks, low-loss base station antennas, missile guidance systems, digital radio antennas, and filters, couplers, and LNAs.

When to Choose Arlon AD Series

The AD Series was built around the telecom infrastructure market, particularly base station antenna manufacturing at commercial volumes. If your design requirements include:

• Multi-carrier antenna systems where PIM is a specified limit
• Large-panel, high-volume production where per-panel cost matters
• Applications with wide ambient temperature swings where Dk stability is critical
• 5G base station feed networks and distributed antenna systems
• Designs using BGA or other area-array components that are sensitive to X-Y CTE mismatch

…then the AD Series is the natural fit. The higher weight ratio of fiberglass to PTFE resin in the AD Series yields laminates with greater dimensional stability than is normally expected of PTFE-based substrates. The stability of PTFE over a wide frequency range and low loss makes AD Series materials ideal for a variety of microwave and RF applications in the telecom industry.

Application Summary Table

Application	Recommended Series	Grade
Precision microwave filters	DiClad	880
Low-noise amplifier circuits	DiClad	880, 870
Power dividers and combiners	DiClad	870, 880
Multilayer RF with tough PTH requirements	DiClad	527
Base station panel antennas	AD Series	AD255C, AD250C
5G multi-band antenna systems	AD Series	AD255C
Automotive radar (volume)	AD Series	AD255C, AD260A
High Dk antenna miniaturization	AD Series	AD300, AD350A
Phased array feeds (precision)	DiClad or AD	527 or AD255C

Fabrication Considerations for Both Series

Both series share PTFE-based processing requirements that differ meaningfully from standard FR-4 work. Arlon’s PTFE laminates are fiberglass/PTFE resin composites used in high-frequency applications where low loss and controlled dielectric constant are required. Using precise control of the resin-to-glass ratio, Arlon is able to offer a range of materials from the lowest dielectric constant and dissipation factor to more highly reinforced laminate having better dimensional stability.

Key fabrication notes that apply to both series:

Surface preparation before lamination is non-negotiable with PTFE materials. Chemical etching or plasma treatment of PTFE surfaces is required for adequate adhesion. Standard FR-4 oxide treatments are not suitable.

Drilling requires PTFE-appropriate parameters — high chip load to avoid smearing, entry and backup materials selected for PTFE, and tooling life management. The ceramic fillers in the AD Series can reduce drill bit life compared to non-ceramic DiClad grades — confirm tooling parameters with your fabricator.

Copper adhesion requires proper surface microstructure. Avoid mechanical scrubbing after etching, which can destroy the micro-roughness needed for bond quality.

AD255C is compatible with the processing used for standard PTFE-based printed circuit board substrates. Its low Z-axis thermal expansion improves plated through-hole (PTH) reliability compared to typical PTFE-based laminates. Low X-Y expansion improves BGA solder-joint reliability.

For production of Arlon PCB designs using either series, working with a fabricator who has documented PTFE process experience is essential. The process sensitivities are real, and fabricators who primarily work in FR-4 often underestimate the differences.

Useful Resources for Engineers

Resource	Description	Link
Rogers AD Series Product Page	Official spec and download page (AD250C, AD255C, AD260A, AD300D, AD350A)	rogerscorp.com
AD Series Datasheet (PDF)	Full electrical, mechanical, and thermal properties	Rogers AD Series PDF
Rogers DiClad Series Product Page	Official product page with DiClad 527, 870, 880	rogerscorp.com
DiClad Series Datasheet (PDF)	Full electrical, mechanical, thermal and panel data	Rogers DiClad PDF
Rogers Laminate Properties Tool	Interactive online selector for comparing all Rogers/Arlon laminates	tools.rogerscorp.com
Arlon Laminate Guide (PDF)	Arlon’s own guide covering DiClad, CuClad, AD Series and material selection	arlonemd.com
Rogers High Frequency Product Selector Guide	Full portfolio guide across all Rogers high-frequency materials	Available on Rogers downloads page
MatWeb – AD255C Entry	Third-party material properties database	matweb.com

Frequently Asked Questions: Arlon AD vs DiClad

1. Can I use DiClad as a drop-in replacement for AD Series in an antenna design?

Not without re-evaluating your design. The DiClad series doesn’t offer grades in the 2.50–3.50 Dk range that the AD Series covers — the DiClad materials sit at Dk 2.17 to 2.65. If your antenna is designed around a specific Dk value, substituting a different Dk will shift your resonant frequency and impedance. Additionally, the AD Series’ better Dk-vs.-temperature stability and lower PIM make it more predictable in production antenna environments. You’d need to re-simulate and re-qualify the design if switching between the two families.

2. Which series has better loss tangent performance at mmWave frequencies?

DiClad 880 holds the advantage at the very low loss end, with Df = 0.0009 at 10 GHz. At mmWave frequencies (above 30 GHz), the dielectric loss contribution grows significantly, making this advantage more meaningful. For sub-6 GHz 5G and typical microwave applications below 20 GHz, the AD Series’ Df = 0.0013 is still excellent and provides better overall system value when PIM and CTE requirements are factored in. For 28 GHz and above designs where every fraction of a dB in dielectric loss matters, DiClad 880 or an alternative ultra-low-loss material should be your starting point.

3. Why does the AD Series cost less than some comparable DiClad grades?

The AD Series was specifically engineered for cost efficiency. Each generation (L → A → C) progressively replaced higher-cost unfilled PTFE resin layers with lower-cost ceramic-filled layers, while actually improving the thermal and electrical properties in the process. The ceramic fillers are cheaper than an equivalent volume of unfilled PTFE. For high-volume antenna manufacturing, this cost optimization was a deliberate commercial decision aligned with the telecom industry’s price sensitivity. DiClad 880, by contrast, maximizes PTFE content to achieve its loss floor — which uses more of the expensive unfilled PTFE resin and is produced in a narrower market volume.

4. Is the DiClad series available as a multilayer stackup material?

Yes, but with an important caveat. DiClad laminates are used in multilayer builds, but the bonding film selection is critical. Compatible Rogers/Arlon bondplies such as CuClad 6700 or CuClad 6250 are required to maintain the dielectric continuity of the stack. The lack of a cross-plied construction in DiClad (unlike CuClad, which offers cross-plied versions of similar materials) means that dimensional stability in multilayer registration needs more careful process management. The AD Series has better dimensional stability from its ceramic loading and is generally considered more forgiving in multilayer constructions.

5. How do I verify which Arlon material grade I’ve received from a distributor?

Request the Certificate of Conformance (CoC) and material test report from your distributor. Authentic Rogers/Arlon materials come with traceable lot numbers and test data. For critical performance applications, Rogers’ “LX” testing grade option (available on CuClad and some other Arlon products) provides individual sheet test data — confirm with your distributor or Rogers directly whether this option is available for your specific grade. If you have doubts about material authenticity or lot consistency, Rogers Corporation’s technology support hub provides technical assistance for material verification.

Summary: AD Series vs DiClad Series at a Glance

The Arlon AD vs DiClad choice ultimately comes down to what your design is optimizing for. The DiClad series — particularly the 880 grade — is built for engineers who need the absolute lowest dielectric loss in a woven fiberglass PTFE laminate, prioritizing precision microwave performance over volume cost and thermal expansion management. The AD Series is built for engineers designing antenna systems and RF infrastructure at commercial scale, where PIM control, Dk stability over temperature, processability at volume, and per-panel cost all matter alongside the core RF performance.

Neither series is universally superior. A precision microwave filter designer and a base station antenna engineer are asking different questions of their substrate — and Arlon/Rogers designed each series to answer a different set of those questions. Pick your material to match your application, not your habit.