As electronic devices continue to advance and become increasingly complex, the cost of printed circuit boards (PCBs) has become a significant factor in a project’s overall budget. While it may not always be possible to cut corners on PCB quality, several strategies can be employed to help reduce the overall cost of these vital components.
This article will explore the top 10 tips for reducing PCB cost, covering everything from design optimization to material selection and manufacturing processes. Following these guidelines makes it possible to achieve significant savings on PCBs without sacrificing reliability or performance. So, let’s get started!
1. Use Standard PCB Sizes & Shapes
Using standard PCB sizes and shapes can help you save on PCB cost during the design process. Standard sizes and shapes are often easier to produce and don’t require as much material, which can save money in both time and resources.
Additionally, when you use standard sizes and shapes, it’s easier to find off-the-shelf components that will fit your PCB, which can also save on cost. There are a variety of standard sizes and shapes to choose from, including FR-4 (Full-size rectangle board), FR-2 (Half-size rectangle board), FR-1 (Quarter-size rectangle board), Square board, Circle board, Round board, and other custom shapes.
You can also consider custom sizes and shapes if you don’t see a size or shape that fits your needs.
2. Use Only Necessary Components
One of the essential tips to reduce PCB cost is to use only the necessary components. When designing a printed circuit board, it can be tempting to include several extra components that you think might be useful in the future. However, this can quickly add to your PCB cost.
Make sure you evaluate the exact components needed and avoid adding any extras. This will help keep the PCB cost down and ensure you are only paying for what you need.
3. Use Surface Mount Components
Using surface mount components can be a great way to reduce PCB cost. Surface mount components are much smaller than traditional through-hole components, allowing for smaller circuit boards and less material usage. This can reduce the overall cost of producing the board.
Additionally, surface mount components allow for more efficient design, which can reduce the complexity of a board, resulting in fewer layers and shorter production times. This can drastically reduce the PCB cost.
4. Minimize the Number of PCB Layers
When designing your printed circuit board, one of the key ways to reduce PCB cost is to minimize the number of layers. The more layers you use, the more expensive the cost. It is possible to reduce the cost by using fewer layers and ensuring all components fit on a single layer.
By using fewer layers, you can also reduce the complexity of the design and make it easier to manufacture.
5. Use Automated Assembly
Automated assembly is a great way to save on PCB cost, allowing for more efficient production. Automated assembly can be used for everything from soldering components onto the board to testing and inspection. It reduces the amount of time and labor needed for assembly, saving both money and time.
Automated assembly also improves accuracy and consistency in the manufacturing process, leading to fewer defects and ensuring that the product meets quality standards. Automated assembly benefits a large volume of PCBs, increasing production efficiency and lowering cost.
6. Use Smaller Vias
Using smaller vias can help to reduce your overall PCB cost. By reducing the size of the vias, you decrease the area of the board needed for the vias and thereby reduce the manufacturing costs. Smaller vias are also easier to manufacture and require less time to create, so the cost per unit is decreased. Additionally, the smaller vias can help with signal integrity as they have lower capacitance and inductance than larger vias. As a result, they are beneficial for high-speed signal integrity applications.
To further reduce your PCB cost, check the minimum feature sizes offered by your chosen PCB manufacturer.
7. Use Online Tools
In today’s digital world, there are a variety of online tools to help you save money when it comes to PCB development. Free automated software can help streamline your PCB design process and make it much easier to complete complex projects in less time. Not only does this save time and money, but it also ensures that you can produce high-quality designs that meet all of your specifications.
Online tools are invaluable for manufacturers looking to reduce their PCB costs. Many companies offer comprehensive libraries of component information that can be used to create custom part numbers and access pricing data for various components.
8. Use Controlled Impedance
Controlled impedance is a term used to refer to the characteristics of an electrical signal in relation to its distance of travel across a printed circuit board. This is an important consideration concerning PCB cost because it can affect the speed and efficiency of a system.
It also affects how much power is needed to run the circuit. By utilizing controlled impedance, you can decrease the amount of power required to run a system and increase signal propagation speed. Additionally, this technique can help reduce the number of traces and vias on your circuit board, reducing your PCB cost.
9. Consider the Cost of Test and Inspection
PCB cost is not just limited to the materials and components you use. Testing and inspection are also essential aspects of any PCB development project. It is crucial to account for the cost of testing and inspection when calculating the overall cost of your project. The cost of testing and inspection can vary greatly depending on the type of tests required, the complexity of the board, and the number of boards being tested or inspected.
It is vital to research the cost of these services before embarking on any PCB development project to budget for them accurately. This can help you to save costs in the long run.
10. Get Quotes From Multiple Sources
When looking to reduce the cost of your PCB project, it is vital to get quotes from multiple sources. Comparing quotes from different suppliers can help you get the best deal possible. Getting multiple quotes also allows you to assess which supplier can provide you with the best quality components while still keeping costs low.
Consider if their services include on-site assembly and testing and whether they offer discounts for bulk orders. Make sure to consider any additional fees, such as shipping, taxes, and inspection costs, when calculating your total PCB cost.
Wrapping Up!
Reducing PCB cost is a crucial part of successful PCB design and development. Utilizing these tips can save money during the design and production process, ensuring that your project is on-time and on budget. Ultimately, careful planning, research, and preparation can help you save costs when dealing with PCBs. With the right combination of components, processes, and materials, you can reduce your overall PCB cost and get the most out of your project.
