PCB Prototyping Pricing and Considerations

1. Introduction to PCB Prototyping

1.1 Definition of PCB Prototyping

PCB prototyping refers to the trial production of printed circuit boards before mass production. It is mainly used by electronic engineers who, after designing their circuits and completing the PCB layout, request a small-scale trial production from a factory—this process is known as PCB prototyping. Engineers typically refer to the process as PCB prototyping before the product design is finalized and testing is complete.

In simple terms, prototyping means creating samples. PCB prototyping is the process of turning a designed PCB schematic into a physical board, which serves as a product test before mass production. A PCB project involves many components, and if any one of them encounters an issue, it can easily affect the overall product development timeline. The same applies to PCB manufacturing. Typically, when developing a project, the designed PCB is sent to a prototype manufacturer for prototyping. A few boards are made for testing, and if the tests are successful, mass production can proceed at a significantly lower cost. Prototyping is mainly focused on speed.

1.2 PCB Prototyping Files

PCB prototyping files usually include PCB files or Gerber files, as well as specifications for production—such as the number of layers, materials, pad technology, ink color, and whether impedance matching is required.

1.3 PCB Prototyping Lead Time

The typical lead time is around 7 days, with expedited options available:

· Single or double-sided boards: 3-4 days to ship.

· Four-layer boards: 6-7 days to ship.

· For mass production, the timeline varies depending on the factory’s capacity, generally around 8-10 days.

2. PCB Prototyping Pricing

2.1 PCB Prototyping Price: Standard Process for 0.6-1.6mm Thickness

2.2 Sample Pricing Calculation:

The total cost of PCB prototyping is typically calculated as follows:

· Engineering Fee + (Board Fee × Quantity) + Film Fee + Surface Treatment Fee + Special Process Fee

3. PCB Prototyping Specifications

The following factors are generally included in PCB prototyping specifications: PCB single board size, PCB panel size, PCB material number, quantity of prototypes, board material, board thickness, copper thickness, surface treatment, solder mask ink color, text ink color, environmental requirements, fire rating, whether vias are filled, hole size tolerance, board warping tolerance, and shaping methods. A few key specifications are listed below:

3.1 Materials:

The type of material used in PCB manufacturing must be specified. The most common material is FR-4. Other special materials include Rogers, Taconic, PTFE, and high-frequency boards like F4B.

3.2 Layers:

Specify the number of layers required for the PCB.

3.3 Solder Mask Color:

There are several colors available depending on company requirements, with green being the most common.

3.4 Silkscreen Color:

Specify the color of the silkscreen text and borders on the PCB, with white being the typical choice.

3.5 Copper Thickness:

The thickness of the copper is scientifically calculated based on the current in the circuit. Thicker copper is generally better but increases cost, so a reasonable balance is necessary.

3.6 Via Solder Mask Coverage:

Specify whether the vias are insulated with solder mask; otherwise, the vias will remain uninsulated.

3.7 Surface Coating:

Options include tin spraying, OSP, immersion tin, immersion gold, and gold plating.

3.8 Quantity:

Clearly specify the number of PCBs to be manufactured.

4. Notes on PCB Prototyping

4.1 Thoroughly check PCB files to avoid issues with the design.

4.2 Ensure full process approval and coordinate with the manufacturer to confirm production processes.

4.3 Control production quantity to save costs while ensuring quality.

4.4 Maintain effective communication with the manufacturer to prevent unforeseen issues.

5. Choosing a PCB Prototyping Method

PCB prototyping can be done in three ways: via standard PCB factories, specialized prototype companies, or a few reverse engineering companies.

5.1 Standard PCB Factories:

Their goal for prototyping is to secure mass production orders. They generally expect follow-up orders, and if you have a large batch to produce, they are a suitable choice. However, they may not focus on making small quantities of samples quickly.

5.2 Specialized Prototype Companies:

These companies specialize in making samples or small batches, offering professional and fast services. They are ideal for one or two sample boards. However, they are not equipped to handle large-scale orders.

5.3 Reverse Engineering Companies:

Some reverse engineering companies also engage in PCB prototyping. After submitting design documents and confirming the final plan with the client, they quickly provide PCB prototypes, functional prototypes, and testing to ensure feasibility.

6. Market Distribution of PCB Prototyping

The demand for PCB prototyping is concentrated in regions where electronics production is highly developed. Major cities with significant PCB prototyping demand include Jiangmen(江门), Huizhou（惠州）, Shanghai（上海）, Shenzhen（深圳）, and Guangzhou（广州）.