Introduction
PCB assembly is the manufacturing process of attaching electronic components to PCBs.
Whether well-versed or novice in this process, you may ask about its costs. What factors play a part in the costs? You may also inquire how to reduce PCB assembly (PCBA) costs.
It’s pivotal to have this information. It’s because it helps to create an accurate cost estimate of the process. Moreover, it will also be advantageous to cut the overall charges.
So, let’s explore.
How much does PCB assembly cost?
PCB assembly, on average, costs between $0.02 and $0.05/square inch. It depends on several factors, including design complexity and labor expenses. Most PCB assembly expenses usually involve buying electronic components like capacitors and resistors. It also depends on how affordable or pricey the parts you choose are.
Furthermore, the time for PCB assembly depends on the project’s size and complexity.
You should pay more if selecting complex designs with several layers and smaller components. Keep reading to learn more about the main factors influencing PCBA cost.
Factors that determine PCB assembly cost
PCB assembly costs depend on several distinct factors. Understanding these is vital for better cost management and insightful decisions.
Here are some vital factors:
1. Material Selection
Note that the cost of PCB is directly proportional to the material type selected. It plays a noteworthy role in price besides the reliability and performance of electronic devices.
In this regard, some important aspects are:
- Selecting PCB’s substrate material affects the price. For example, materials like FR-4 are cost-efficient and range from $1-$8 per square foot. Meanwhile, specialized substrates like ceramic or flexible materials are more expensive. An example is ceramic ones that cost $5-$50 per square foot.
- In PCB, the thickness of the copper layer can influence the price. Thin copper can cost around $5-$20 per square foot. Meanwhile, thick copper is priced around $20-$50.
- Solder paste quality is crucial for reliable solder joints in the PCBA. High-quality solder paste costs around $40-$80 per jar or syringe, while standard solder paste costs around $20-$50.
2. Manufacturing costs
The manufacturing processes needed for your custom PCB project can remarkably impact the cost. Consider complex processes like:
- Controlled impedance traces
- Specialized surface finishes
These have higher manufacturing costs than those of standard production techniques and processes.
3. Design complexity
The complexity of the PCB design can significantly affect the assembly cost.
For example, consider designs with:
- multiple layers
- dense component placement
- fine traces
All these need advanced production techniques that can markedly raise the cost. Using features like blind vias and controlled impedance can also lead to complexity in design. It can notably increase the cost of PCB assembly.
4. Surface Mount Technology
A vital aspect of PCBA costs is the variant of technology used. As you see, SMT (Surface Mount Technology) can lead to cost savings for manufacturers. It’s because there are low setup costs, and the process is heavily automated and efficient.
Conversely, the costs of THT (through-hole technology) are higher than those of SMT. This is because THT requires more time to punch holes on the boards.
Yet, SMT can result in the outcome of through-hole drilling. The purpose is to fit added SMDs (surface mount devices), which can raise costs.
Thus, consider your project needs before the process and select the fitting assembly technology.
5. Labor costs
You may know that PCB assembly needs skilled human processes and automated machines. Thus, the labor costs are very consequential for this process.
The geographical location where the process is carried out impacts labor costs. Thus, manufacturers tend to produce Printed Circuit Boards in areas with cheap labor.
For instance, ponder a PCB assembled in Western Europe or North America. It’s usually more expensive than the one assembled in South Asia.
Furthermore, overseas manufacturing can raise PCB assembly costs due to handling and shipping delays. Yet, cheap manufacturing can also have unexpected costs that need to be considered. Also, consider this before you sign a contract with an overseas manufacturer.
6. Turnaround time
By turnaround time, we mean the time needed to accomplish the manufacturing process. Thus, the buyer’s request is completed.
You can see that a speedier turnaround time costs more. It can raise the PCB assembly costs by up to 33% or more. It means that manufacturers must prioritize your order and put others on hold.
Thus, speedier shipping, which decreases the turnaround time, is more expensive than standard shipping.
7. Production volume
High production volume costs lower in manufacturing owing to economies of scale. It means that when products are made in large volumes, each PCB’s unit price drops.
It occurs because manufacturers can prevent one-time costs like startup charges. In such a case, these charges don’t need to be reproduced. Thus, it helps in saving the expenses of PCB assembly.
Yet, you should always look up those manufacturers that can provide large order volumes.
8. Testing and quality control
Strict testing and quality control steps can add to the overall cost of PCBA. Yet, these are critical to make certain the circuit board assembly’s reliability. It may include automated optical inspection (AOI) and functional testing.
These inspections can add about 10-15% to the project’s overall cost. Furthermore, complying with industry standards or certifications can further increase the PCB assembly cost.
9. Parts packaging
Parts packaging is another factor that affects the PCBA costs. Packaging of different parts and components will result in different PCB assembly costs.
Note that some components need more workers to fulfil the packaging requirements completely. For instance, BGA needs more time and effort to complete packaging. It’s because they must be linked to a power supply.
The BGA’s electrical pins are X-rayed to check for problems like short-circuiting. Thus, it will greatly increase costs compared to packaging for other parts.
What is the typical cost per assembled board?
You see that the typical cost per assembled board varies between $5 to $50. As discussed before, the price depends on several factors. It includes design complexity, labor, production volume, and material selection, to name a few.
The cost of simpler boards in larger volumes ranges between $2 and $10 per board. However, it’s imperative to consider the manufacturer’s quality.
How do we reduce PCB assembly costs?
You now know the PCB assembly costs and the typical price per assembled board. Now let’s delve into some guidance to reduce the PCB assembly costs:
1. PCB design
You can begin reducing costs on PCB assembly by designing PCBs optimally. Some noteworthy factors that can affect the final cost of bare PCBs include:
- Size
- Shape
- Layer count
- Via technology
- Type of surface finishing
By redesigning these elements, you can reduce costs when producing Printed Circuit Boards. You may know that vias are used to build connections on the PCBs. Opting for buried or blind vias will affect the product’s price.
Similarly, opting for surface-mount components rather than through-hole PCB assemblies can save costs. Furthermore, using fewer layers can aid in cost savings.
2. PCB layout estimation
Some factors affect the PCB layout cost. You can sometimes avoid considering these factors in the base assembly quote, which can lead to higher project costs or even abandonment.
Some of these factors are:
- The count of parts and net count gives a starting point for determining PCB cost.
- Confirming the proper layout requires careful planning of components like the smallest-pitch BGA and highest pin count.
- Few digital interfaces have distinct design rules to ensure meeting performance metrics.
- Unique RF (Radio frequency)structures like waveguides need very watchful design and layout. In turn, these can have additional requirements that can increase the cost.
- Added engineering design services can lead to a separate quote.
3. Comprehensive bill of materials
Creating a comprehensive bill of materials (BOM) is a vital thing. It can significantly help to manage the production costs. It includes all the components and subparts that are needed for PCB production.
Using a PCB design checklist is a good idea. It aids in knowing if your BOM has all the required items. It can include reference designators and part numbers. A comprehensive BOM also include replacement parts for every component.
Thus, you can better manage resources and make better decisions about manufacturing while saving costs.
4. Order timing and quantity
Order timing and quantity are crucial factors that determine the PCB assembly costs. If you place larger orders, you can reduce the PCB assembly costs. The reason is that you can avoid paying the setup fee for each new order. It can be done by ordering plenty of boards at once.
The larger the volume, the lesser the unit price, owing to economies of scale.
Note that not all manufacturers can meet your order timing and quantity. They may lack the resources to successfully meet a larger order. Discuss this in advance with a manufacturer before placing an order.
Be easy-going with respect to order timing. The goal is to reduce the assembly costs while following your product’s PCB design limits.
5. Inspection and testing
It’s paramount that you inspect and test the products. The goal is to prevent defective Printed Circuit Boards from being brought into the market. Otherwise, it can lead to the cost of bringing about refunds. It can also significantly harm working relationships with the clients.
If you decide to skip inspection and testing, the cost will outweigh any cost savings. After all, there’s no point in shrinking expenses if your product quality declines.
Also, a trace width calculator can be used to precisely regulate the traces’ temperature. It’s in the PCB’s external and internal layers. With suitable inspection and testing protocol, you can lessen long-term risks. It makes sure that your circuitry performs reliably in different temperature conditions.
Conclusion
By now, you should have plenty of knowledge of the costs involved in PCB assembly.
You also learned about the many factors that play a part in these costs. Lastly, you also got to know how you can reduce PCB assembly costs.
In summary, such costs range from $0.02 to $0.05/square inch and are determined by several factors. These include material selection, design complexity, and labor costs.
Being prudent about these considerations is critical for prosperous electronic projects.