2022-12-21
What factors will affect the cost of PCB production?
There are several factors that can act as drivers of PCB manufacturing costs. Understanding the stages of PCB production and processing can help you make cost-effective decisions that can ensure the quality of your products while saving money.
1. PCB size
The size and shape of the PCB will affect the increase in cost. Expanding the size of the PCB will require more materials and time to manufacture the final product, resulting in higher costs. The price of a PCB increases proportionally with the surface area of the board, which you can use to figure out how much your product will cost extra when you expand beyond the standard size.
2. Efficient use of materials
Effective use of materials is closely related to size and spacing. When you choose a smaller size PCB, you will use less material, making it a more cost-effective choice. However, even if you choose to go with a larger size, you can reduce material costs by using your available space efficiently to reduce waste and only use what you need. Finding an arrangement that optimizes your space and size can help ensure you only use what you need.
3. Number of layers
There are a number of reasons for the increased cost of adding additional layers. As you add more layers, each layer requires more material and more etching and bonding steps.
Also, adding more layers generally increases the chances of a PCB having defects during the testing phase, so your manufacturer may take this into account in their quote when you request a multi-layer board. Your manufacturer will need to inspect each layer, adding to these costs.
4. Complexity
The further your PCB moves from standard and conventional board technology, the higher your costs. More complex configurations and designs will require more time and additional assembly steps.
While simple PCBs may require one of each processing step, complex PCBs may require three or four additional steps that simple boards do not, such as laser drilling. They may also require specialized personnel or equipment, which will cost more.
5. Material selection
Depending on the material you choose, you will experience price fluctuations. Some materials are more cost-effective than others and can save you PCB production costs. While you may need some higher quality materials for specific board functions, choosing the materials that best fit your budget can help keep costs down.
6. Line width and line spacing
The routing of the PCB is essential as it is responsible for its electrical carrying capacity. However, how the traces are arranged on the PCB and how the design relates to the available space affects the price. Tighter production lines are more challenging for manufacturers, leading to higher prices for these services.
7. Size and number of holes
Many hole-related factors can cause you to pay more for PCB fabrication, but hole size is the most prevalent. Smaller holes are more challenging and require more specialized training and tooling, resulting in higher costs. When the hole reaches a certain size, a laser is needed to achieve precision.
This will cost your fabricator more time when you have more holes, leading to further cost increases. Also, with multiple layers or thicker materials, you can expect higher costs to accommodate the necessary fabrication time.
8. Control impedance
Like trace tightness, controlled impedance requires the design and production of very specific or uniform trace widths and spacings. Many factors in these processes can lead to higher prices, from the specific materials needed to achieve the desired results to the necessary testing procedures.
9. Tight tolerances
When you have tight tolerances in your PCB design, it automatically increases the complexity of your board, which already leads to higher costs. Additionally, tight tolerances can sometimes lead to board mounting or functional assembly issues, resulting in troubleshooting costs.
10. Copper thickness
The thickness of copper foil is closely related to the effective utilization of materials. Thicker copper foils are more expensive and introduce additional challenges and costs. You may need to use more prepreg during the processing step to fill the gaps between the copper. Because thicker copper is heavier, you may also encounter higher shipping costs.
11. Solder mask, silk screen, carbon printing
When designing a PCB, you should consider the production steps a manufacturer will need to complete it. Including solder mask, silk screen and carbon printing all require separate processes, which will require more time investment.
Prices also vary if the process requires specialized equipment or tools. For example, if you choose a higher quality or thicker solder mask, the material drives up the price.
12. Surface treatment
Depending on the surface finish you choose for your PCB, the cost can fluctuate. You can find standard and basic finishes like OSP and HASL that are more cost effective and still have good solderability. However, some other finishes may increase the price.
LF HASL, Imm Ag, Imm SN, and ENIG vary in price, with LF HASL being the best deal and ENIG the most expensive. Also, the price depends on how many layers of each material are required. Choosing a more cost-effective finish can help you reduce PCB manufacturing costs.
Understanding what drives up PCB manufacturing costs can help you find cost-effective boards that meet your functional needs and industry standards.
1. PCB size
The size and shape of the PCB will affect the increase in cost. Expanding the size of the PCB will require more materials and time to manufacture the final product, resulting in higher costs. The price of a PCB increases proportionally with the surface area of the board, which you can use to figure out how much your product will cost extra when you expand beyond the standard size.
2. Efficient use of materials
Effective use of materials is closely related to size and spacing. When you choose a smaller size PCB, you will use less material, making it a more cost-effective choice. However, even if you choose to go with a larger size, you can reduce material costs by using your available space efficiently to reduce waste and only use what you need. Finding an arrangement that optimizes your space and size can help ensure you only use what you need.
3. Number of layers
There are a number of reasons for the increased cost of adding additional layers. As you add more layers, each layer requires more material and more etching and bonding steps.
Also, adding more layers generally increases the chances of a PCB having defects during the testing phase, so your manufacturer may take this into account in their quote when you request a multi-layer board. Your manufacturer will need to inspect each layer, adding to these costs.
4. Complexity
The further your PCB moves from standard and conventional board technology, the higher your costs. More complex configurations and designs will require more time and additional assembly steps.
While simple PCBs may require one of each processing step, complex PCBs may require three or four additional steps that simple boards do not, such as laser drilling. They may also require specialized personnel or equipment, which will cost more.
5. Material selection
Depending on the material you choose, you will experience price fluctuations. Some materials are more cost-effective than others and can save you PCB production costs. While you may need some higher quality materials for specific board functions, choosing the materials that best fit your budget can help keep costs down.
6. Line width and line spacing
The routing of the PCB is essential as it is responsible for its electrical carrying capacity. However, how the traces are arranged on the PCB and how the design relates to the available space affects the price. Tighter production lines are more challenging for manufacturers, leading to higher prices for these services.
7. Size and number of holes
Many hole-related factors can cause you to pay more for PCB fabrication, but hole size is the most prevalent. Smaller holes are more challenging and require more specialized training and tooling, resulting in higher costs. When the hole reaches a certain size, a laser is needed to achieve precision.
This will cost your fabricator more time when you have more holes, leading to further cost increases. Also, with multiple layers or thicker materials, you can expect higher costs to accommodate the necessary fabrication time.
8. Control impedance
Like trace tightness, controlled impedance requires the design and production of very specific or uniform trace widths and spacings. Many factors in these processes can lead to higher prices, from the specific materials needed to achieve the desired results to the necessary testing procedures.
9. Tight tolerances
When you have tight tolerances in your PCB design, it automatically increases the complexity of your board, which already leads to higher costs. Additionally, tight tolerances can sometimes lead to board mounting or functional assembly issues, resulting in troubleshooting costs.
10. Copper thickness
The thickness of copper foil is closely related to the effective utilization of materials. Thicker copper foils are more expensive and introduce additional challenges and costs. You may need to use more prepreg during the processing step to fill the gaps between the copper. Because thicker copper is heavier, you may also encounter higher shipping costs.
11. Solder mask, silk screen, carbon printing
When designing a PCB, you should consider the production steps a manufacturer will need to complete it. Including solder mask, silk screen and carbon printing all require separate processes, which will require more time investment.
Prices also vary if the process requires specialized equipment or tools. For example, if you choose a higher quality or thicker solder mask, the material drives up the price.
12. Surface treatment
Depending on the surface finish you choose for your PCB, the cost can fluctuate. You can find standard and basic finishes like OSP and HASL that are more cost effective and still have good solderability. However, some other finishes may increase the price.
LF HASL, Imm Ag, Imm SN, and ENIG vary in price, with LF HASL being the best deal and ENIG the most expensive. Also, the price depends on how many layers of each material are required. Choosing a more cost-effective finish can help you reduce PCB manufacturing costs.
Understanding what drives up PCB manufacturing costs can help you find cost-effective boards that meet your functional needs and industry standards.
