PCBs are an integral part of almost every modern electronic gadget. You will find PCBs in smartphones and laptops, as well as in cars and home appliances. But before a PCB becomes a working part of a product, it must go through a process called PCB assembly. Have you ever wondered: How much does PCB assembly cost?
Actually, many beginners assume that PCB assembly costs are fixed. But in reality, they can vary widely depending on several factors. That’s why understanding the cost of PCB assembly is essential for managing your budget effectively. In this article, I will discuss typical price ranges for PCB assembly and the factors that affect them. So, let’s get started!
How Much Does PCB Assembly Cost?
The costs of PCB assembly vary widely and are not fixed. However, on average, for simple PCBs in small quantities, it might cost $50 to $200 per board. For moderately complex PCBs, the cost ranges from $10 to $50 per board. Lastly, for large volumes, the price per PCB ranges from $2 to $20.
Basically, PCB assembly is the process of taking a blank circuit board and adding all the parts it needs to work. These parts can be tiny chips, resistors, capacitors, or connectors. By putting these parts on the board and connecting them, the PCB becomes a working part of an electronic device.
It’s important to know that PCB assembly is not just about the board itself. When starting PCB assembly, you are also covering labor, soldering, and basic testing. These steps ensure that every component is placed correctly, enhancing PCB capabilities. When estimating the overall cost of PCB assembly, you have to consider all these factors.
Factors that Affect PCB Assembly Costs
As I said above, the cost of PCB assembly is not fixed. Several essential factors influence it. Before you plan your PCB assembly budget, consider these factors.
1- Design Complexity Of the PCBs
The complexity of a PCB is one of the most significant factors that affect how much it costs to assemble. Basically, complexity means how complicated the board design is. Remember, the more complex the PCB design, the more it will cost and vice versa. How? For example, a single-sided PCB with just a few components and a simple layout does not require extra care.
It takes less time, reduces the cost of complex parts, and also reduces labor costs. On the flip side, a board with many layers and hundreds of tiny parts takes longer and requires more effort. For example, a PCB with 4, 6, or even eight layers has more connections inside. So, it’s harder to create and assemble those layers. Also, if your PCB has a higher component density with tightly packed parts, it needs advanced equipment for assembly. This further adds to the overall PCB assembly cost.
2- Quantity or Volume
The number of PCBs you order, also known as the quantity or volume, significantly impacts assembly costs. The concept is very simple: the more boards you make, the lower the cost per board. Why? This is because some costs, like machine setup, programming, and preparation, are fixed. No matter whether you buy one PCB or a hundred PCBs, these costs will remain fixed.
So when you produce more boards, these fixed costs are spread over many PCBs. As a result, the price per PCB reduces. On the other hand, if you need to make fewer PCBs, you still have to set up all those machines and programs. As a result, the expense is divided among fewer boards. It means the cost per PCB increases. In my view, producing in larger volumes is more efficient and saves money.
3- Bill of Materials (BOM) or Component Cost
The Bill of Materials (BOM) is basically a complete list of all the parts and components that go onto your PCB. Those components usually include resistors, capacitors, chips, connectors, and more. So the total cost of these components is a big part of the overall PCB assembly cost. How? Suppose your PCB assembly requires standard, easy-to-find parts; the price will be lower.
On the flip side, if you need specialized or high-tech components, prices can go up quickly. Not only does the type of components matter, but also the number of components. If your PCB requires hundreds of parts, they will cost more. Moreover, mounting a large number of parts takes more time and effort, thereby increasing the overall cost.
4- Assembly Method
The method you use to assemble the PCB is another factor that highly affects the cost. There are mainly two types of assembly. Those include Surface Mount Technology (SMT) and Through-Hole Technology (THT). SMT uses machines to place small components directly on the board surface. This setup requires higher initial costs. However, it is a fast and efficient method, making it less expensive, especially for larger quantities.
THT, on the other hand, involves placing components into holes and soldering them in place. This process usually takes more time and often requires manual labor. So generally, THT is more expensive. Some boards use a combination of both SMT and THT, known as hybrid assembly. In such cases, you get flexibility in design. However, it also adds extra steps, time, and cost.
5- Lead time & Special Services
Lead time is the time it takes a manufacturer to complete your PCB assembly order. If you need your boards very quickly, such as for urgent projects, it will cost more. WHY? Because they prioritize your work and speed up the production. For this, manufacturers may hire extra labor or work overtime, which directly increases PCB assembly costs.
Additionally, special services can affect PCB assembly costs. Special services mean extra work or added care that goes beyond the basic assembly. These are optional services that you may choose depending on your project’s needs. For example, some projects need every PCB to be tested very carefully. This could include functional tests, electrical tests, or visual inspections. These tests enhance the overall cost of PCB assembly.
In addition, if your boards are fragile or sensitive to moisture, you will need protective packaging. This special packaging can also increase PCB costs. Moreover, some boards need labels or custom markings for identification or tracking. All these extra services raise the overall PCB assembly cost.
6- Materials & Manufacturing Country
The materials used to make your PCB play a significant role in the overall assembly cost. Different types of boards require different qualities of materials. For example, PCBs made with standard materials might cost less. But boards made with specialized materials, such as flexible PCBs or high-temperature boards, will cost more.
Moreover, the quality of the material also matters. High-quality PCBs come at higher prices. However, they last longer, which can compensate for higher prices. Beyond this, the country where your PCB is manufactured also impacts the price. Labor costs, local regulations, and shipping all vary from one country to another. For example, countries like China are known for lower labor and manufacturing costs.
It means that PCBs made there can be cheaper, especially for large orders. On the other hand, PCBs made in countries like the U.S. are usually more expensive. This is because labor and materials cost more there. But these countries often have high production standards and stricter quality control. This reduces mistakes and the need for rework, which saves costs in the long term.
Tips to Reduce PCB Assembly Cost
PCB assembly costs are not fixed. If you notice that the overall cost of your PCB assembly is high, you can reduce it. How? Let’s explore some practical strategies to reduce PCB assembly costs.
- Simplify Your Board Design: One of the easiest ways to reduce PCB costs is to keep the design simple. A simple PCB design with few layers and components requires less time and effort to manufacture. This speeds up the production process, thereby reducing the cost per board. So I suggest that if you are working on a light project, keep the PCB design simple.
- Order in Larger Quantities: Buying more boards at once can lower the cost per PCB. Actually, manufacturers have certain fixed costs. Those include setting up machines, programming equipment, and preparing materials. These costs remain the same whether you order one board or 100 boards. So when you order more PCBs, these fixed costs are spread over all the boards. As a result, PCB costs are reduced.
- Choose Standard Components: You should always choose standard components for PCB assembly. These components are easy for manufacturers to source and usually cost much less than rare ones. Moreover, standard components also make assembly faster and more efficient. As a result, the overall cost of PCB assembly reduces.
- Work With Experienced Manufacturers: Partnering with experienced manufacturers can save you money. Experienced companies know how to assemble PCBs quickly and correctly. They make fewer mistakes, which means your PCBs work efficiently. It means you don’t have to pay extra to fix problems. An experienced manufacturer can also give you helpful advice. They can suggest cheaper parts or better design approaches to reduce costs.
- Optimize Testing and Quality Control: Testing is essential for PCB assembly. However, doing too much testing or overly advanced inspections can increase costs. Remember, not every PCB needs every test type. Sometimes, regular checks are enough to make sure the boards are reliable. So I recommend taking your manufacturer’s advice and deciding on only the necessary tests, along with a few quality tests.
Frequently Asked Questions
Can I assemble PCBs at home?
Yes, you can assemble simple design PCBs at home if you have some know-how. For this, you will need simple tools like a soldering iron, tweezers, and flux. However, for a complex PCB, such as a double-sided PCB with many small components, you should seek professional help.
Is PCB assembly fully automated?
Not always! PCB assembly can be fully automated, partially automated, or even manual. It mainly depends on the nature of the project. Large-scale production usually uses automated machines for speed and accuracy. However, small batches or prototypes may still involve some manual steps.
How long does PCB assembly usually take?
PCB assembly time can vary depending on the complexity and quantity of the boards. Simple prototypes might take a few days. However, large or complex production runs can take one to two weeks. But if you request your manufacturers for urgent projects, they can speed up the assembly process. However, it will cost you more.
Conclusion
PCBs are among the most critical components of every electronic device. However, when working with PCBs, many get confused about PCB assembly costs. Hence, in this article, I have discussed the average price range of PCB assembly. But remember, these prices are not fixed. Instead, they vary with several factors. For example, if you choose the simple PCB, it will cost less than a complex one.
At the same time, the quality and type of PCB component materials affect the cost. However, the good news is that the higher PCB assembly cost can be reduced. By simplifying your design and using standard components, you can save money without losing quality. That’s what I always recommend before assembling or buying a PCB: do a little planning, and it will pay off for a long time.