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PCB insights

Understanding PCB cost drivers – a guide for smart procurement

Image of two printed circuit boards (PCBs)

As an engineer or buyer responsible for sourcing printed circuit boards (PCBs), you know that costs can vary significantly between fabricators and designs. While getting quotes from multiple vendors is important, having a solid grasp of the key cost drivers will allow you to make more informed sourcing decisions upfront. This knowledge enables you to optimize your designs for cost-effectiveness and ensures you receive apples-to-apples quotes that meet your requirements.

In this guide, we'll explore the major factors that influence the costs of your PCB – empowering you to control expenses through smart design choices and transparent communication with fabricators. Note that this article focuses on the PCB design and layout phase as well as the sourcing and procurement phase, rather than the product development phase.

Layer count – the starting point

Hand holding a printed circuit board (PCB) showing the complexity of the layout

The foundation of any PCB cost estimate is the layer count. Each additional layer requires more materials, imaging, etching, and plating steps – directly translating to higher prices. For common low-layer count boards (e.g. 4-8 layers), this base layer cost is relatively low. However, for high-layer boards like those exceeding 14 layers, costs rise exponentially.

The fluctuating price of copper significantly influences overall costs, alongside other materials like the substrate and solder mask. Each component's quality and specifications can lead to variations in price, making material choice a strategic decision in PCB procurement.

Material selection – balancing cost and performance

Not all laminates and copper weights are created equal. While standard FR4 remains the most cost-effective solution for many applications, high-frequency RF/microwave designs or harsh operating environments may require more specialized (and expensive) materials. Carefully evaluating your performance requirements allows you to use affordable base laminates wherever possible while deploying advanced (so-called “exotic”) materials only where absolutely necessary.

Similarly, copper weights beyond 1oz drive costs up dramatically due to increased etchant requirements, tighter tolerances needed, and limits on fabrication capabilities. Reviewing your current specifications could reveal opportunities to use lighter copper weights for non-critical layers.

Drill complexity – holes add up quickly

With drilling being one of the most labor and tooling-intensive steps, hole sizes, counts, and types can be a major cost factor. Reducing hole densities and standardizing sizes will improve economies of scale. Avoiding tiny holes allows to the manufacturer to drill more PCBs in a stack, and hence decreasing the processing time e.g. cost.

Additionally, buried/blind vias require extra lamination cycles and precisely controlled processing – making them an order of magnitude more costly than simple through-holes.

PCB technology – a key cost factor

The technology employed in PCB fabrication can significantly impact costs. Advanced technologies such as high-density interconnect (HDI) PCBs, flexible PCBs, and rigid-flex PCBs come with higher fabrication costs due to their complexity and the specialized equipment required.

  • High-density interconnect (HDI) PCBs
    HDI PCBs, which include features such as microvias, blind/buried vias, and via-in-pad designs, offer higher wiring density and better electrical performance. However, the sophisticated processes and precision needed for HDI manufacturing result in higher costs.
  • Flexible and rigid-flex PCBs
    Flexible and rigid-flex PCBs provide design versatility and reliability in dynamic applications, but their production involves more complex steps, such as layering polyimide films and precise adhesive application, contributing to increased costs.

Via filling – value vs cost

While specs sometimes mandate vias filling, the different types of via filling and plugging, as well as material used can greatly affect the price- benefit performance. Discussing your application's actual needs may open the door to cost-saving alternatives and proposals.

Board size – manufacturing efficiency matters

All else being equal, larger PCBs require more materials and carry inherently higher fabrication costs. However, optimizing panel utilization by fitting your design into standard production panel sizes can drastically reduce material waste and improve manufacturing efficiency.

Special requirements – extras add up

Controlled impedance demands, edge plating, board scoring/routing, and other unique requirements can incrementally increase costs through additional testing, materials, and processes. Being judicious about specifying such extras only when truly required will keep costs in check.

Team of three men holding a printed circuit board (PCB) discussing cost aspects

Production techniques and volume effects

Production methods, from traditional etching to modern direct imaging, influence PCB costs. Volume plays a decisive role, with larger orders typically benefiting from economies of scale. However, the shift towards more specialized, low-volume orders in some sectors has reshaped cost structures, emphasizing the need for flexibility in manufacturing capabilities.

Cost reduction in sourcing and procurement

Sourcing and procurement strategies can have a significant impact on overall PCB costs. Here are key considerations:

  • Finding the right manufacturer: The process can be overwhelming due to the variety of options available. It's crucial to select a manufacturer that meets your quality, cost, and lead time requirements.
  • Technical requirements: Prices can vary significantly depending on technical specifications, such as the number of layers. For instance, a 2-layer PCB with standard laminate and 35µm base copper is more cost-effective compared to a 4-layer PCB with mid TG laminate and 70µm base copper.
  • Supplier onboarding process: A structured onboarding process ensures that suppliers meet necessary quality standards. This includes major production steps, checked items, and function usability reliability (FUR) relevance.
  • PCB quality management: Implementing robust quality management controls and tests can prevent costly failures. This includes qualification tests, thermal stress tests, temperature cycling tests, and more.
  • Preventive quality investments: High investments in preventive quality and continuous quality management are necessary to strive towards a zero-failure strategy. While preventive costs might exceed failure costs, the focus should be on safety and reliability.
Navigating PCB costs requires a strategic approach, balancing technical requirements with budget constraints. Collaboration with suppliers, leveraging volume discounts, and optimizing Design for Manufacturing are key strategies in achieving cost-efficient sourcing.

Why partner with copperdot?

By developing a strong understanding of key cost drivers and leveraging this guide, you'll be able to have more productive conversations with your PCB suppliers from initial design reviews through sourcing. This transparent collaboration ensures you receive accurate, comprehensive quotes that account for all relevant factors - letting you make the most cost-effective sourcing decisions for your PCB needs.

copperdot offers several advantages in PCB procurement in being a service offered by Bosch. By consolidating orders with Bosch's internal requirements, copperdot can leverage substantial production volumes, potentially leading to cost savings without compromising quality. This means also that your PCBs are subject to the same tests and conditions as the Bosch PCBs that are incorporated in our own products "Invented for life".Furthermore, copperdot employs an advanced, AI-driven IT platform that automates end-to-end procurement processes, reducing operational errors, costs, and streamlining communication, resulting in more reliable and efficient PCB sourcing. Additionally, copperdot offers a Design for Manufacturing service throughout the procurement journey, ensuring that your designs are optimized for cost-effective and efficient production.

Beyond mere component supply, copperdot aims to be a strategic partner by leveraging its extensive expertise in PCBs and market trends. We provide tailored solutions that focus on enhancing product performance and keeping clients ahead of industry developments, thus contributing to their continued competitiveness.

Our team will be happy to advise you on any of the aforementioned topics and share our knowledge and expertise to ensure functionality, usability, and reliability combined with efficient and stable manufacturability.

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