The performance of every electronic device depends on the structure of its PCB. The structure of a PCB board depends on how professionally you assemble it. Just using high-quality parts is not enough. You must ensure this assembly works appropriately in the right environment. And here, essential issues like PCB assembly cost come into play.
PCB Assembly, or PCBA, is a crucial term in PCB manufacturing. PCB assemblers, like UETPCB, always strive to provide the highest-quality assembly service. PCBA has three main types: THT, SMT, and Mixed. THT stands for Through-Hole Technology. SMT stands for Surface Mount Technology. However, mixed methods combine THT and SMT.
The THT method is the most robust solution, but complex manufacturing is needed. Because of this, the cost of THT PCBA is usually higher than that of other methods. On the other hand, SMT is a much cheaper solution, but SMT PCB boards are unsuitable for motion or vibration-related uses. So, each method has its unique cost constraints.
This article aims to highlight PCB assembly costs. It will discuss the factors that affect this pricing. Moreover, you will learn how to estimate and reduce this cost. Overall, this article will be an excellent guide for your project.
Average PCB Assembly Cost
The cost of a printed circuit board assembly ranges from $0.02 to $0.05 per square inch or $31 to $78 per square meter. The final price may depend on the PCB design, materials, and order quantity. This price may vary when using standard components or asking for rush orders.
Including the component sourcing and labor costs, the price for small batch orders may range from $20 to $2000. This price may range from $10 to $50 for medium quantities. However, you may have to count from $2 to $30 for larger quantities.
Key Factors Affecting PCB Assembly Cost
As already mentioned, the PCB assembly cost may vary. Let’s find out what the key factors heavily affect this cost.
#1 PCB Desing and Complexity
The first thing every PCB assembler should do is assess the overall design plan. Based on its complexity, they plan for production lines. A few PCBs, like microelectronics, require unique production lines. On the other hand, some PCBA may need dust control environments and special tooling.
On the other hand, single-sided boards are generally cheaper. Their production process is also very simple. In contrast, multi-sided PCB board assembly is much more complex. They need additional manufacturing steps, increasing the overall PCB assembly cost.
Moreover, larger PCBs need more materials, which also increases the cost. On the other hand, smaller boards need fewer materials, offering cheaper solutions. However, a smaller PCB doesn’t always mean cheap; a high-density PCB with multi-layer features may be even more costly.
Small PCBs, like 2×2 or 4×4, may cost around $5 to $20. Medium ones may cost around $10 to $30. On the other hand, larger PCB fabrication assembly may cost $20 to $200 or even more.
#2 Materials Used in PCB Board Assembly
What kind of materials you are using also matters. However, the most common choice is the FR-4, which is relatively cheaper. However, if you consider choosing ceramic or flexible PCBs, these might increase the PCB assembly cost.
A FR-4 substrate usually costs $10 to $100 per square meter. On the other hand, ceramics range from $10 to $50 per square meter. Flexible PCB materials, like PTFE or Polyimide, cost $3000 to $31K per square meter.
Also, thicker copper materials used for traces may increase the cost. The use of gold for high-frequency PCBs also adds a significant cost. If you choose 1oz or 2oz, the price may range from $50 to $200 per square meter. On the other hand, 4oz or above copper traces may cost from $200 to $500 per square meter.
Moreover, if you are concerned about the environment, you might opt for lead-free solder paste. However, this solder material is more expensive than general or standard options. High-quality solder paste may cost around $40 to $80 per bottle. On the other hand, the cheaper solution may cost around $20 to $50 per bottle.
#3 Component Selection and Sourcing
Standard components are always easy to source. However, custom or hard-to-find components usually cost around five times or even more than the standard ones.
Also, sourcing the standard components is faster, eventually offering shorter lead times. However, hard-to-find components or custom components need more time to manage. Because of this, you can not expect faster delivery or a cheaper outcome.
#4 SMT or THT?
As mentioned, SMT, or Surface Mount Technology, allows you to install parts on the surface of the PCB. This method is much cheaper than other methods. On the other hand, THT or Through Hole Technology needs complex installation, which adds extra PCB assembly costs.
Depending on your project needs, you must decide between these or both. It is critical to note that many modern PCB board assemblies use a mix of both technologies. This way, you can balance the PCB’s cost and robustness.
#5 Turnkey or Consignment?
Turnkey PCB assembly is a complete PCBA service. This service includes everything from sourcing the materials to the assembly. It means that a single PCB assembler manages the entire functional PCB process.
Consignment PCB assembly is different from turnkey. You will provide the necessary parts or components in this approach. The PCB assemblers will not take responsibility for the quality of the parts and components.
Turnkey PCB assembly is easier. You don’t have to worry about managing the necessary parts. Thus, including the components charge, Turnkey PCB assembly typically costs more. On the other hand, consignment PCB assembly is a comparatively cheaper solution.
#6 The PCB’s Thickness and Aspect Ratio
Besides the materials discussed above, why does PCB thickness matter? As you know, the more layers you have, the more stacking processes are maintained.
Thicker boards over 2mm need more materials and laminations. It raises the overall PCB assembly and manufacturing cost. Thinner PCB boards under 0.8mm, on the other hand, save money. However, thinner PCB boards are typically less durable than the thicker ones.
The aspect ratio is another crucial factor to consider here. High ratios need accurate drilling, which requires precision tooling machines.
#7 Labor Costs and Manufacturing Locations
Most Asian countries offer cheaper labor costs, like in China. Since the labor cost is not that high, like in Europe or America, the overall PCB assembly cost is also lower in these countries.
Besides, manual and automated labor matters significantly for the overall assembly process. Most SMT PCB assemblies are automated. These machines can assemble components incredibly faster than other manual labor. This automation approach typically reduces the cost of PCB assembly service.
#8 Testing and Custom Quality Control Requirements
Most basic testing is initially included in the whole service package. However, it may cost more if you need special standards, which are usually not common international standards. For example, Russian standards are generally acceptable in Russia and a few countries. However, most factories follow ISO, EN, or other common standards.
How to Estimate PCB Assembly Cost
Considering all the factors that affect the PCB assembly cost can help you estimate the final price. The total cost is the sum of all these factors. Once you have the total cost, you can divide it by the total number of PCBs to get the price per unit.
Total Cost = Component Cost + labor + overhead + materials + testing + Quality control + profit
Component costs depend on the type & quality of the parts you use. For example, resistors, capacitors, and ICs are priced differently. Some components are cheap, and some are specialized. Labor and overhead depend on the assembly factory location. The materials, testing, and quality control depend on your personal preferences. And finally, every company keeps a certain profit level, starting at 10% and continuing to 50%.
How to Reduce PCB Assembly Cost
First, you must pay attention to the design to reduce the cost of the PCB assembly. Try to make it as simple as possible and balance the functionality your project needs. Then, use the standard materials, components, and layout sizes. Until it is necessary, try not to make thick-layer PCBs.
Ordering in bulk is another effective way to save money. A smaller quantity costs more, while a larger quantity significantly reduces the price per unit. Also, you must choose the right PCB assemblers for your business. In today’s world, precision and productivity matter a lot. Some PCB assemblers are still outdated and do not use modern technology. Because of this, they can not offer you a good precision result and faster delivery time.
Summary
It is crucial to understand how PCB assembly costs. By understanding it, you can plan your budget wisely. In this case, key factors that go up ahead are design complexity., materials, component choices, and assembly method. You must balance and find the optimized solution between cost and quality. Cheaper quality can not always make you win. There are some reliability issues.
To reduce these expenses, try to simplify your PCB design. Opt for standard items and order for larger quantities. Automated assembly is much more cost-effective. Therefore, choose an appropriate PCB assembly manufacturer who can offer reliability and good business.
If you have any questions, feel free to contact us. Our team of experts is always happy to assist you.