Some of the biggest influences that affect PCB Manufacturing Cost

By | Date posted: | Last updated: January 18, 2023
PCB cost

When it comes to Printed Circuit Board Assembly, there are a host of factors that determine its cost. Beginning with the technology used to the number of components, there are an array of aspects that directly impact the cost. However what is often forgotten are a number of indirect factors that also add to the PCB Assembly Cost. These factors include areas such as lack of testing equipment for example or even lack of trained manpower. Best practices such as lack of Design for Assembly as well as design for Manufacturing can also go a long way in positively impacting efficiency and negatively impacting cost. At the design stage itself, components need to be chosen with utmost care. Similarly the placement of these components can have a bearing on costs. Ensuring that you Design for Manufacturing, for example also goes a long way in eliminating issues at the design stage itself, as well as keeping costs under control. If not done correctly, aspects such as the design and placement of components could significantly affect costs. Check out the guide on how to reduce PCB assembly cost.

Here is a quick overview of some of the factors that impact PCB Manufacturing Cost:

  • Technology Used in PCB –

    Assembly process may use Surface Mount or Through Hole Technology. Sometimes though some assemblies may require both these technologies to be used, adding to the cost.

  • Single or Double Sided board –

    A Single sided board assembly cost would typically be lower than one where you use a double sided board.

  • Number of placements –

    Costs can typically increase with the number of placements required

  • Size of PCB components –

    Typically smaller components and densely packed assembly boards add to the cost.

  • Availability of components –

    It stands to reason that cost is also impacted by the (non)availability of components.

  • Compliance –

    Often times testing to ensure assembly compliance also adds to the cost. Compliance such as RoHS and non- RoHS, IPC-A-610D Class I, II or III ITAR are often required, adding to the cost.

  • PCB Assembly Process needs –

    Some PCB Assemblies could need a host of processes such as:

  • Wave Solder
  • X-Ray
  • Automated Optical Inspection
  • Hand Solder, and other such processes. These could add to the cost significantly.

  • Flexible or rigid PCB Assembly –

    Typically flexible PCB Assembly cost is higher than that of a rigid one.

  • Coating –

    Cost is also impacted by the coating requirements. Aspects such as whether you are using spray or a brush, the number of coats required, impact the cost.

  • Testing –

    From thermal cycling to in circuit tests, there are a number of tests required before the PCB can be shipped. The testing in turn have a direct correlation with costs.

  • Flexible or rigid PCB Assembly –

    Whether you need special containers or electrostatic discharge bags, once again can add to the costs

  • Delivery –

    In case express delivery is required, costs are likely to increase.

Top tips to be kept in mind so that PCB manufacturing can be kept under check:

  • Look for multiple component sources –

    This will help you to source components at the lowest cost without sacrificing efficiency. It will help to set up a process between the design engineering and purchase departments in order to ensure that conflicting priorities do not lead to a lack of cost optimization. Setting up cost reduction committees for example, could go a long way in identifying opportunities for cost reduction without of course negatively impacting efficiency.

  • Ensure that you do a Design-for-Manufacturing test –

    This will take into account multiple factors at the design stage itself. Optimizing the bare board schematic will mean checking for areas such as:

    • Complexity
    • Number of holes and their size
    • Via tech
    • Material
    • Layer Count

  • Prepare a complete BOM –

    Simply put, the PCB bill of materials (BOM) as it is popularly called,is a list of parts and components used on the PCB. A complete Bill of Materials including details such as part number, manufacturer name, quantity, description, component replacements etc. can significantly expedite the quotation process, as also help source components at the right price. A thoroughly prepared BOM means lesser time spent back and forth and therefore greater efficiency.

  • Order Value and lead time –

    Costs are typically inversely proportional to order value and lead time. Planning well in advance so that you can request for quantities at one go as also ensuring that you have enough lead time will help in controlling costs.

  • Inspection –

    Even though testing and inspection adds to the cost, skimping on the same can have larger repercussions. Some manufacturers can offer in house inspection which can save you the time and hassle of getting a third party to inspect the boards.

Technotronix offers professional PCB Assembly services with 40 years of expertise. Our accurate PCB assembly process meets the quality standards, including ISO-9001:2015, RoHS, and more. You can rely on our PCB design tools that, in turn, lead to that perfect PCB Assembly. Our superior engineering capabilities mean that each board matches your exact requirements and technical specifications. If you have any questions or any requirements related to PCB assembly service, please feel free to contact us via email at sales@technotronix.us or call at 714/630-9200.

Why choose Automated X-Ray Inspection (AXI) Technology in PCB Assembly?

By | Date posted: | Last updated: April 8, 2022
AXI Technology In PCB

Simply put, Automated X-ray inspection or AXI technology as it is popularly referred to, uses X-rays to inspect the features of target objects. As an application, it finds place in a whole lot of industries today including but not limited to aerospace, medical, PCB Assembly and more.

X-rays go a long way in testing PCB quality as traditional inspection devices have their own limitations especially when miniaturization is on the increase. Also there are added issues of solder joints being hidden in some cases. X-rays however can penetrate and inspect quality of hidden solder joints as well. Therefore, while Automated Optical Inspection is only applicable for defects that are relatively easy to spot, such as open circuits or solder bridges, Automated X-ray inspection is required where inspection isn’t possible basis light alone.

The advantage with X-rays comes on account of the fact that materials absorb X-rays proportional to their atomic weight and depending on their density and thickness. Heavier elements thus absorb more X-rays as compared to lighter ones. Hidden defects, therefore, such as those to do with missing electrical components, shorts etc are far easy to catch.

An ideal X-ray system however must have clear images so that information with respect to defect analysis is clear and actionable. It is ideal, therefore, that the X-ray inspection system has adequate magnification as well as oblique angle inspection function. The latter ensures that solder balls aren’t just inspected from above.

X-ray inspection devices typically come in two forms- two- dimensional and three-dimensional systems. Both these can be operated off line and therefore make the inspection process easy. Some devices however can be used online. The choice of offline versus online devices typically depends on the amount of inspection required. In cases where there are large quantities to inspect and the level of inspection is complex, online devices are generally used. While a two-dimensional system can display 2D images of components from both sides, a three-dimensional system can generate images of cross sections. 3D systems can also combine images of a cross section in a method known as laminography.

The kind of resolution required also necessitates the need to choose the right X-ray tube, which is typically available in two categories- open and closed. Also the amount of magnification required determines the distance between the sample and X-ray tube. The X-ray voltage is yet another determinant of its penetration capacity. With a large voltage, objects with high density and thickness can be inspected easily. With single sided boards, however it is enough to go with low voltage. Similarly multi-layered boards call for high voltage.

The early inspection devices came with an image intensifier linked to a CCD Camera, the image intensifier, however, came with the following constraints:

  • Limited range- The limited range in turn implies that the area may need to be inspected with more than one technique. This in turn increases the time taken to satisfactorily carry out the inspection.
  • Limited field of view- At a given point in time a three to five inch diameter areas can be inspected.
  • Image blooming- There is a chance of the image bleeding at the edges as the ionizing radiation passing by the edge of the casting is not attenuated
  • Increased Noise levels- The image intensifier produces a noisy image. A clean, noise free image necessitates a digital processing of the image, which in turn is time consuming and does not let the process remain real time.

The above constraints however can be mitigated with the use of a direct digital imaging device. It not only offers a larger inspection area but also an improvement in resolution.

WITH X-RAY INSPECTION, WE CAN DO THE FOLLOWING:

  • Perform a non-destructive inspection
  • Locate short circuits
  • Detect voids in solder joints
  • Determine displacements of components
  • Examine semiconductors
  • Check switches, relays , plug and cable connections

 

The advantages of Automated X-ray inspection technology are as below:

  • Reliable and consistent results
  • Reduced time for inspection
  • Reduction in labour cost.
  • Effective process control as defects can be found in the early stage of the PCB assembly process and that it stops defects from flooding among the remaining PCB assembly.

 

Overall, therefore, X-Ray inspection technology is certainly a boon for PCBA manufacturers as it helps them improve product quality significantly. With the need for sub-micron resolution and extremely high definition images at high speed, the need for and the complexity of X-ray inspection technology will only grow. The way forward will be to be able to reduce the number of expensive operators as also remove the probability of human errors, if any, in the inspection process. This can be achieved by developing some inspection algorithms to be able to tackle these complexities.

At Technotronix, we are fully equipped to handle your PCB manufacturing requirements. With over 4 decades of experience in PCB manufacturing as well as PCB assembly with differing levels of complexities, we follow industry best practices to ensure we deliver cutting-edge products. Our team of experts and state-of-the-art equipment ensures that all our PCBs meet the industry standards of quality and testing. It is our vast portfolio of satisfied clients that stand as the biggest testimony to our success. In case if you have any questions, please feel free to contact us via email at sales@technotronix.us

Why Small Batch PCB Assembly should become your preferred method for all kinds of industrial projects?

By | Date posted: | Last updated: April 8, 2021
Small Batch PCB

With Printed Circuit Boards becoming an integral part of more and more devices, PCB prototyping is at an all time high. With companies continuously innovating, the need of the hour is small batch PCB Assembly which can offer high turnaround times without the manufacturer being stuck with high inventory that he is unable to make use of.

Advantages of small batch PCB assembly that are of immense value to a manufacturer:

Cost advantage

Although traditionally economies of scale are known to accrue with high volume of production, in an ever-changing technological scenario low volume PCB production comes with significant cost advantages. For one, you will not land up getting more boards produced than you require. Also, with changing technology the boards won’t be rendered redundant.

At the prototype stage, you are often improvising on the product, both in terms of design and functionality. Low batch production means that you aren’t stuck with faulty products. Also, since you are able to outsource PCB small batch. PCB Assembly, what it means in terms of your own business is lower overhead costs. You can also save on precious time that can be utilized in other productive areas of business. With lower batches you also tend to save on storage costs that can accrue in case you are stuck with a heavy inventory load, which is also dead inventory if the prototypes are faulty. Small batch PCB Assembly can therefore offer a low-cost testing method. A Small batch PCB Assembly can therefore offer a low-cost testing method. Check out Top Manufacturing Factors that Affect the Cost of Custom PCB Assembly.

Turnaround time

Low volumes also come with quick turnaround times. You can therefore assess if there are any design changes to e made, quickly. This, in turn leads to shorter time to market, which in today’s world can be a source of significant competitive advantage.

Agility

If there is one attribute that stands between business success and failure, it is agility of businesses to respond to changes. Small batch PCB Assembly inherently offers this advantage to businesses as businesses aren’t stuck with high volume of production as well as have the advantage of quick turnaround times. With improved ability to see whether there are any flaws in the product, whether the design needs any changes, businesses can be extremely agile in dovetailing the product to suit customer needs. Needless to say that the chances of success are increased manifold.

Quality Final Product

With quick turnaround time of PCB prototypes and the ability to detect flaws early, you have the advantage of improving the products and therefore to go to the market with quality products. This goes a long way in improved credibility as the product is successful in the market place and brings repute to the manufacturer.

Feasible for startups and hobbyists as well

Business these days is no longer the realm of large business houses alone. With small batch PCB assembly and the low costs associated with testing out ideas, business has become a level playing field. It is easy for small businesses as well as hobbyists to test their ideas with ease without having to invest large sums of money. For startups wanting to pitch to investors, it is also easy to have a proof of concept beyond just a business plan on paper.

To summarize, PCB small batch comes with multiple advantages, beginning from saving overhead costs by outsourcing your work. Small order sizes automatically lead to improved turnaround times. Also, it is an easy and low-cost way of testing product design ideas without incurring a whole lot of cost.

Technotronix offers professional Custom PCB Assembly with 40 years of expertise. Our accurate PCB assembly process meets the quality standards, including ISO 9001:2015, RoHS, and more. Our superior engineering capabilities mean that each board matches your exact requirements and technical specifications. In case if you have any questions, please feel free to contact us via email at sales@technotronix.us

Request a quote for Custom PCB Assembly!

The Choice of PCB Assembly plays a major role in speeding up or slowing down supply chain

By | Date posted: | Last updated: February 15, 2023
PCB For Supply Chain Speed

When it comes to supply chain management, a single weak link can impact business. If you are in the electronics business, printed circuit board assembly can very often become that weak link.

In choosing the PCBA supplier, it is therefore imperative that you are able to go with the one who can safeguard quality all right but also someone who can use their body of experience to ensure supplier efficacy throughout the supply chain.

Another major advantage of choosing the right PCBA is also that they can use their experience to audit not just PCB layouts but also the prototypes. What it means in turn is that they help align the engineering schematics with speed considerations early on, enabling you to go to market faster

While the above factors will help you choose the PCBA with prudence, here are some of the things you can do to ensure that the supply chain is speeded up:

#1 Have proper communication channels

When you are on a tight deadline, there is little scope for a communication breakdown. Ensure therefore that communication with the PCBA is clear and responses are not delayed. It is best to avoid assumptions as far as possible and put everything in clearly understandable terms, well in advance as far as possible.

In fact good partnering practices with your PCB supplier include:

  • Routine conference calls between your team and that of the PCB supplier
  • Quarterly Reviews that are designed to review the performance metrics and any business updates. Ideally this can be a two way process with updates being shared from both sides related to any business growth, new products and more. Essentially any information that impacts the production process as well as the business relationship needs to be shared.
  • Supplier score cards with objective and subjective metrics is yet another process that should be maintained. Things such as on-time delivery, defect rates as well as communication issues and more should be flagged off from time to time so that everyone is aware of issues, if any.
  • You also need to ensure that the supplier has a quality improvement program in place with periodic reviews.

The above best practices will ensure that the process is kept under check and also that the equation with the PCBA is that of partnership and not just of a vendor.

#2 Ensure that your documentation is complete

Ensure that you have worked through your documentation well in advance and that the documentation includes the following:

  • Bill of Materials – Do remember to go by the format that the supplier prefers
  • Gerber Files
  • XY data file
  • Stencil Files
  • Special assembly instructions

If there are any sub-assemblies that need to be manufactured in advance, it is also imperative that you have a bill of materials for each sub assembly and estimate the lead time for the parts. It is also important to verify their compatibility with the finished product

Try and avoid any last minute changes to ensure that everything is in order well in advance.

#3 Identify parts which have long lead-time

Ever so often electronic components have long lead times, often running into months. Identifying these components early can help the PCBA look for either alternate parts or source suppliers who have shorter lead times. In turn this can help cut lead times significantly as also impact costs.

#4 Forecasting demand

Keeping the PCBA posted on the demand forecasts instead of waiting to inform them of out of stock products at the last minute can also go a long way in keeping cost in check. It is commonly known that express shipping can come at a far higher cost and can derail the overall costing. Keeping the supplier posted on demand forecasts, on the other hand can offer the lead time to procure supplies at efficient rates.

#5 End to end partnership

Look for a PCBA who can provide end-to-end solutions and can assist you right from the conceptualization to the production phase. This will streamline the entire process and will cut down time.

The above steps when followed can ensure that the PCB Assembly process and the PCB Assembly provider does not become the weak link in your supply chain and is instead recognized as a critical part of the entire operation.