When designing and manufacturing PCBs,
PCB cost is one of the aspects we care about most. Only by understanding the
cost of PCBs can we better control the budget of electronic projects. So,
exactly how much is a circuit board? In fact, this depends on many factors,
such as whether the design is complex, what materials are used, and the later
assembly and testing.
This guide will detail the key factors
that affect the PCB cost, including PCB manufacturing and assembly prices. We
will also introduce how to use the PCB cost estimator to help you understand
the cost of custom circuit boards and share some practical methods to reduce
the price of circuit boards.
What Is Included in PCB Cost?
When we talk about PCB cost, it is not as
simple as just buying a bare board. The complete PCB board cost usually
consists of the following three main parts.
PCB Fabrication Cost
This part is the cost of manufacturing
the circuit board itself. It will be affected by multiple factors, such as the
type of material used (such as FR-4, CEM-1 or Rogers), the number of layers,
the size and shape of the board, the thickness of the copper, the surface
treatment method (such as HASL, ENIG, OSP), as well as the number of holes or
cutouts. The higher the material grade, the more layers, and the more complex
the design, the greater the difficulty and then the manufacturing cost will
increase accordingly. All of these will directly determine your PCB fabrication
cost and overall PCB manufacturing cost.
PCB Assembly Cost
This part is the cost of assembling
components onto the circuit board. It includes processes such as SMT assembly,
THT insertion, and soldering. If there are many components, the packaging is
complex or high-precision mounting is required (such as BGA and QFN), the
requirements for equipment and processes will be higher, and the PCB assembly
cost will also become more expensive. Especially in the case of small-batch or
multi-variant
production, the costs of machine setup and labor costs will be spread over each
board, significantly increasing the PCB assembly price and also affecting the
overall circuit board cost.
Engineering & Tooling Cost
This is the cost that must be invested
before actual production begins. It includes service fees for DFM file checks,
production of solder paste stencil, development of testing fixtures (such as
ICT or FCT tools), as well as services for programming or functional testing.
These belong to one-time engineering preparation costs. However, if the order
quantity is very small, these fixed costs will significantly increase the cost
of the single board.
Key Factors Affecting PCB Fabrication Cost
PCB manufacturing cost depends on many
technical details. Every design choice can change the final price. Below are
the most important factors:
1. Number of Layers
The more layers a PCB has, the more
complex it is to make. More layers mean more pressing, drilling, and alignment
steps. For example, a 2-layer board is simple and cheap. A 6-layer or 8-layer
board is harder to make, so the printed circuit board cost is higher. If you
don't need many layers, try to stick with 2-layer or 4-layer boards to lower
the PCB manufacturing cost.
2. Board Size and Shape
Larger boards use more materials and take
more time to produce. This increases the circuit board cost. Non-standard
shapes, like curved edges or custom cutouts, also require extra processing
steps. This adds to the PCB manufacturing cost. To save money, use standard
sizes and simple shapes when possible.
3. Material Type
The most common material is FR-4. It’s
affordable and works for most projects. But if you need high-frequency,
high-heat, or flexible boards, you may need materials like Rogers or polyimide
(PI). These materials are more expensive and harder to process. That’s why they
increase your PCB cost.
4. Surface Finish
Surface finish affects soldering quality
and board lifespan. Common finishes are HASL (hot air solder leveling) and ENIG
(electroless nickel immersion gold). HASL is cheaper and good for basic needs.
ENIG costs more but prevents oxidation and supports better soldering. Choosing
ENIG will raise your PCB board price.
5. Copper Thickness
Thicker copper allows more current to
flow through the board. Standard copper thickness is 1oz (about 35μm), which
works for most applications. But power boards may need 2oz or 3oz copper.
Thicker copper needs more materials and more complex processing. That makes the
PCB manufacturing cost and PCB fabrication costs higher.
These choices shape your total PCB manufacturing
cost structure. It’s important to plan carefully during the design stage. Smart
decisions here will help keep your budget under control.
PCB Assembly Cost Explained
PCB assembly cost is the cost of turning
a bare board into a fully functional product. Several key factors affect your
PCB assembly price:
Component sourcing
If you ask the manufacturer to buy
components for you, the cost will depend on availability and lead time. If
there's a chip shortage or you need special parts, the PCB assembly cost can
increase a lot.
Assembly method
Surface Mount Technology (SMT) is usually
cheaper than Through-Hole Technology (THT). But if your board uses both, that's
mixed assembly, and it will raise your overall PCB cost.
Labor and machine setup
For low-volume orders, setup costs are
spread across fewer boards. This makes the PCB assembly price per unit higher
and increases the total circuit board cost.
Testing requirements
Functional testing, AOI (Automated
Optical Inspection), and X-ray inspection add to the PCB manufacturing cost.
But they are very important for ensuring product quality.
So, when you evaluate PCB assembly cost,
be sure to include these hidden but important factors. They can have a big
impact on your final PCB board cost.
About PCBasic
Time is money in your projects – and PCBasic gets it. PCBasic is a PCB assembly company that delivers fast, flawless results every time. Our comprehensive PCB assembly services include expert engineering support at every step, ensuring top quality in every board. As a leading PCB assembly manufacturer, we provide a one-stop solution that streamlines your supply chain. Partner with our advanced PCB prototype factory for quick turnarounds and superior results you can trust.
Custom PCB Cost: What Makes It Expensive?
Custom PCB costs are usually higher than
standard ready-made boards. There are a few main reasons for this:
Complex routing.
If your PCB has very tight traces, fine-pitch components, or needs impedance
control, it's harder to manufacture. This increases the custom circuit board
cost.
Non-standard stack-up.
Some multilayer boards use special dielectric materials or custom layer
structures. These are more difficult to produce and raise the PCB manufacturing
cost.
Prototype orders.
Small-batch custom prototypes are less efficient to produce. The setup and
tooling costs are spread over fewer boards, which raises the PCB board cost per
unit.
So, if you're wondering "how much
does a custom circuit board cost," the answer is: usually much more.
Especially for low-volume or complex designs, the custom PCB cost will be
significantly higher.
How to Estimate PCB Cost Accurately at PCBasic
There are many factors that affect PCB
cost, so using a PCB cost estimator is the best way to get a fast quote.
PCBasic provides an online calculator to help users estimate their own PCB
manufacturing costs.
Steps to use the cost calculator:
1. Enter
board size, number of layers, and material
2. Choose
surface finish and copper thickness
3. Set
the quantity and delivery time
4. Check
the quote for PCB fabrication cost and PCB assembly price
A fabrication cost calculator makes it
easy to see how your design choices affect the circuit board price. But for
large or complex projects, it’s better to request a manual quote. This gives
you a more accurate PCB manufacturing cost breakdown.
Cost Optimization Tips
Lowering your overall PCB cost doesn’t
mean you have to sacrifice quality. Here are some practical ways to reduce your
printed circuit board cost:
1. Optimize your design
Smaller board sizes and fewer layers help
lower your PCB fabrication cost.
2. Use standard specifications
Avoid non-standard board thickness or
special surface finishes. These will increase your circuit board cost.
3. Order in bulk
Larger orders reduce the PCB board price
per unit. You also get better cost efficiency in both manufacturing and
assembly.
4. Use panelization
Combine multiple small PCBs into one
large panel. This reduces setup time and helps cut down your PCB manufacturing
cost.
5. Do in-house assembly
If possible, assembling simple boards
yourself can greatly lower your PCB assembly cost.
Using these strategies lets you control
PCB costs while still keeping good quality and getting a more competitive
circuit board price.
Conclusion
So, exactly how much is a circuit board?
As shown in this article, the PCB cost varies due to manufacturing parameters,
assembly complexity, order quantity and design details. By understanding the
various factors that affect the PCB manufacturing cost and the assembly price
and making good use of reliable PCB cost estimators, you can better control the
PCB cost of your project.
