The main factors affecting the cost of a tan circuit board
The price of PCB is a matter that many buyers have always been confused about. Many people will wonder how these prices are calculated when placing an order. Let’s talk about some factors that make up the PCB price.
- The price difference caused by different materials used in PCB
Take ordinary double-sided boards as an example. The main board material now uses FR4 (Shengyi, Jiantao, Guoji, three prices from top to bottom), the board thickness ranges from 0.2mm to 3.0mm, and the copper thickness ranges from 0.5oz to 3oz. PCB has caused a huge price difference in these board materials; in terms of solder mask ink, there is also a certain price difference between ordinary thermosetting oil and photosensitive green oil. - The price difference caused by different PCB surface processes
Common ones are: OSP (anti-oxidation), lead tin spraying, lead-free tin spraying, gold plating, immersion gold, and some complex processes, etc.; the more the previous production process is, the mor e expensive it is. - Different PCB design standards cause price differences
There are 800 holes on both PCBs. If the hole diameter of one board is greater than 0.2mm and the hole diameter of the other board is less than 0.2mm, it will also cause different drilling costs. If the other two PCBs are the same, but the line width and line spacing are different, one is greater than 4mil and the other is less than 4mil, it will also cause different production costs. There are also some designs with different process flows from the ordinary ones that also charge extra fees, such as keypads, carbon printing oil, half holes, buried blind holes, and disk holes. - Different PCB copper foil thickness causes price differences
The commonly used copper foil thicknesses are: 18um (1/2OZ), 35um (1OZ), 70um (2OZ), 105um (3OZ), 140um (4OZ), etc. The thicker the copper foil, the more expensive it is. - Customer quality acceptance standards
Commonly used are: IPC2, IPC3, enterprise standards, military standards, etc. The higher the standard, the higher the price. - Mold fee and test rack
1) Mold fee: For prototypes and small batches, the board factory generally adopts drilling and milling, and will not charge additional milling fees. When doing mass production, it is required to open a mold to punch the board, which improves efficiency and reduces production costs. The cost of a set of molds is about 800.
2) Test fee: The prototype generally adopts flying probe testing, which is generally free for the board factory now; for batches, it is necessary to open a test rack to improve efficiency. Improving efficiency and reducing production costs will also reduce the test rack. The general quotation is about 1200. - Different payment methods will also cause price differences
The payment method with a shorter arrival time will have a lower price, such as cash payment. - Order quantity/delivery period
1) Order quantity: The smaller the quantity, the more expensive the price will be, because even if it is 1PCS, the board factory must prepare engineering data and produce film, and no process is missing.
2) Delivery period: Short production time for the factory will also increase production costs.
3) Provide the PCB factory with complete production data (GERBER data, number of board layers, board material, board thickness, surface treatment process, ink color, character color and some special requirements should be clearly written)
Methods for estimating the cost of tan circuit boards
“How much does a PCB cost?” Such questions make people wonder what methods can be used to estimate the cost of PCB manufacturing. When early estimates are needed before involving suppliers, PCB cost calculators prove to be the most reliable solution. However, the final pricing should be based on the quotes provided by manufacturing partners.
Supplier Quote
Getting price quotes directly from manufacturing partners is the most accurate way to estimate PCB costs. It involves direct communication with manufacturers, which enables precise quotes to be customized according to the specifications of the project. However, this method requires sharing detailed design files, allowing manufacturers to assess complexity and provide accurate cost estimates based on materials, production processes and project-specific specifications.
PCB Cost Calculator
Similarly, using online PCB cost calculators can provide a range of PCB price estimates by inputting key parameters such as size, number of layers, quantity, finished products and delivery time.
Cost Estimation Expertise
Experienced engineers can provide estimates based on previous builds. Although the estimates provided are fast, they may lack reliability.
Costs between Production Capacities
Production capacity significantly impacts PCB manufacturing costs, leading to the distinction between prototype, low-volume, and high-volume production.
- Prototyping
Prototyping involves testing and validation of small batches, which is more expensive due to one-time setup costs and smaller order quantities. - Low-volume production
Low-volume production strikes a balance between cost-effectiveness and large order quantities, allowing adjustments based on prototype testing and reducing board costs compared to prototypes. - High-volume production
High-volume production benefits from large scale, with larger order quantities making it easier to spread fixed costs over more units, resulting in a lower price per board.
Impact of Design Decisions on Manufacturing Pricing
Design decisions play a critical role in determining manufacturing costs. Careful consideration of these factors can lead to cost optimization without compromising performance. - Board Materials and Layer Count
The choice of materials and the determination of the number of layers directly impact costs, with advanced materials and higher layer counts adding expense. - Size and Feature Density
The larger the size of the board and the higher the feature density, the more inefficient the panel space utilization, resulting in higher costs. The higher the feature density and the smaller the size of the board, the higher the manufacturing cost. - Final Touches
Various protective treatments such as ENIG and immersion silver also add to the cost. Additional tests such as flying probe testing, X-rays, and cross-sectioning also add to the overall expense. - Lead Time
Tight deadlines can result in a monetary premium, while longer standard lead times are cost-effective for larger order quantities.
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Transferring Data to a Reliable PCB Manufacturer
Are you concerned about the cost of PCB assembly? Wondering if there are any hidden charges to deal with? Well, to know all about this costing process, you must first find a trusted PCB assembly manufacturer.
Don’t be overwhelmed by the number of options you’ll come across. On the contrary, the list can make your decision very difficult because it’s hard to figure out which manufacturer is a good one.
Make sure you have all the following details ready for the manufacturer to analyze: - Number of Boards
- Gerber Files: RS-274X
- Centroid Data
- BOM or Bill of Materials
- Assembly Files
- Unique Features
Methods to Minimize Manufacturing Costs and Maximize Optimized Design Decisions
Optimized design is essential to reduce PCB manufacturing costs without compromising performance. There are several strategies that can be employed for cost-effective PCB design.
- Material Selection
Choosing materials carefully based on project requirements and choosing cost-effective and appropriate materials can help reduce overall costs. - Design Efficiency
Optimizing board size and feature density to effectively utilize panel space and minimize unnecessary complexity can help reduce PCB manufacturing expenses. - Manufacturing Process
Based on requirements and specifications, PCB manufacturers can select the appropriate manufacturing process and avoid unnecessary processes and technologies that lead to increased costs. - Testing and Inspection
Choosing the level of testing and inspection that meets project requirements and avoiding over-specifying test requirements can help avoid increased expenses.
Budgeting PCB Manufacturing Expenses
How much a PCB costs enables us to better budget, which is a key aspect of effective project management and resource allocation. - Supplier Selection
Choosing a manufacturing partner based on capabilities, market conditions, and cost-effectiveness can help reduce costs. The larger the production order, the lower the price per board. - Communication with Manufacturers
Open communication with manufacturers is essential to obtain accurate quotes. - Prototype Testing
Allocate a portion of the budget for prototype testing. Although prototypes are more expensive, they provide valuable insights and help improve the design. - Design Trade-offs
Consider the design trade-offs between performance and cost. The necessity of certain features and materials is evaluated to achieve a balance between functionality and affordability.
Factors that influence the cost of assembling tan circuit boards
- Order quantity
The first and most important factor is to determine the order quantity so that it is easy to apply the formula – the larger the quantity, the lower the price.
When you plan to order 50 pieces for a 10 x 50 mm double-sided PCB, the all-in cost will be between $30 and $35, but if the quantity increases to 30 pieces, the unit cost may decrease while the total cost will remain within the above range. What does this mean? Although the total cost has not decreased, the benefit is that the production cost is affordable, which will encourage manufacturers and customers to purchase more quantities within their budget. - Single-Sided or Double-Sided Circuit Boards
The availability of panels on the printed circuit board has a huge impact on the PCB cost, i.e. it increases with each additional layer. Some producers are well aware of the extra costs they have to bear, so they usually change around $16 for a basic double-sided board. However, customers can also choose some customized PCB boards, but this also requires some additional costs. - Materials Used
Manufacturers are well aware of those long-lasting materials that can guarantee performance and productivity for a longer period of time. Most of them use FR-4 because of its ability to face different temperatures. One of the important additions is that FR4-TG150 is around 4% more expensive than regular FR-5, while FR4-TG175 can increase 10% of PCB assembly costs. - Surface Finish
Considering their aggressive use, PCB assemblies must have a corrosion-resistant surface finish. It is important for manufacturers to use customized surface painting, finishing, and coatings to make the surface durable and protected. Sometimes, they go for silver and gold finishes as per your requirements, ensuring the highest layer of protection, especially for industrial applications. Just be sure that this choice will have an impact on the PCB assembly cost calculator results that can be a little unexpected. - Evaluate Reputation
There is no doubt that the internet has become the best source to get as much information about a product or brand as needed. You can easily get to know the best electronics websites and compare the features and prices offered by different manufacturers. Even, you can ask for suggestions for the PCB idea you have in mind. - Inspection Fees
Last but not the least, PCB assembly cost is incomplete without inspection fees. Their goal is to ensure that the components are of good quality in terms of: - Ionic composition
- Electrical properties
- Impedance
Hence, these fees will bring the total PCB assembly cost up by nearly 10% or 15%, no matter how hard the manufacturer tries to keep it as low as possible. Here, the thing to remember is that manufacturers should not compromise on product quality in order to reduce PCB costs.
Inspection Methods
In fact, there are many ways to inspect PCB components. The top 3 of them are:
Automated X-ray Inspection – AXI
Automated Optical Inspection – AOI
Appearance Inspection
Summary
In summary, estimating PCB manufacturing cost is a complex but necessary task in product development. There is a question that people often ask. That is, “How much does a piece of PCB cost?” Considering the important cost drivers, accurate estimation methods, and smart design decisions are essential to the complexity of tan circuit board cost pricing. Whether dealing with prototypes, small batches, or high-volume production, a thorough understanding of cost factors allows for effective budgeting and project management. It is recommended to stay updated on industry trends, utilize online tools, and maintain open communication with manufacturing partners to ensure that cost estimates for PCB projects are accurate and competitive.
