What is the difference between thick film power resistors and thin film power resistors

There are significant differences between thick film power resistors and thin film power resistors in multiple aspects. The following is a detailed comparison:

1、 Manufacturing process
Thick film power amplifier resistor
Using screen printing technology, resistor paste (usually containing metal oxides, glass beads, organic solvents, etc.) is printed on ceramic or glass substrates.
After high-temperature sintering, a resistance layer with a certain resistance value is formed.
Thin film power amplifier resistor
Use processes such as vacuum evaporation, magnetron sputtering, or chemical vapor deposition.
Evaporate or deposit resistive materials (such as nickel chromium alloys, nickel copper alloys, or metal oxides) onto the surface of insulating substrates (such as alumina ceramics, silicon, or glass).
2、 Film thickness
Thick film power amplifier resistor
The thickness of the film layer is usually greater than 10 micrometers (μ m), sometimes reaching tens of micrometers or even thicker.
Thin film power amplifier resistor
The thickness of the film layer is very thin, usually less than 10 micrometers (μ m), and in most cases less than 1 micrometer (μ m).
3、 Performance characteristics
accuracy
Thick film power up resistor: The accuracy is relatively low, with common accuracies of 10%, 5%, 1%, etc.
Thin film power up resistor: with high accuracy, it can reach 0.01% or higher, suitable for circuits with extremely high precision requirements.
temperature coefficient
Thick film power up resistor: with a large temperature coefficient, the resistance value changes significantly with temperature.
Thin film power up resistor: The temperature coefficient is very low, and the resistance value changes very little with temperature, so it has excellent temperature stability.
Noise
Thick film power up resistor: Due to the thick film layer and manufacturing process limitations, the noise is relatively high.
Thin film power up resistor: The film layer is thin and uniform, and the manufacturing process is advanced, so the noise is low.
4、 Application Fields
Thick film power amplifier resistor
Due to its low cost, relatively simple manufacturing process, and certain power bearing capacity, it is widely used in various electronic devices, including communication equipment, computers, household appliances, etc.
Especially suitable for circuit environments with low requirements for accuracy and temperature stability.
Thin film power amplifier resistor
Due to its high precision, low temperature coefficient, and low noise, it is particularly suitable for circuit environments that require extremely high precision and stability.
Such as instruments, medical devices, power supplies, and electrical equipment.
5、 Cost and Price
Thick film power amplifier resistor
The manufacturing process is relatively simple and the material cost is low, so the price is relatively cheap.
Thin film power amplifier resistor
The manufacturing process is complex and requires the use of high-precision equipment and materials, resulting in relatively high prices.
In summary, there are significant differences between thick film power resistors and thin film power resistors in terms of manufacturing processes, film thickness, performance characteristics, application areas, as well as cost and price. When choosing, comprehensive consideration should be given to specific application requirements and circuit design requirements.