Reduce the Cost of Pcb Manufacturing Assembly

The cost of Pcb manufacturing assembly is a key consideration for most electronics designers. This is because the PCB assembly process is not cheap and can quickly add up to a substantial amount of a product’s final price. However, reducing this cost is possible with a few simple steps. The key to lowering costs is the pre-production design phase, which determines fundamental aspects of the circuit board’s structure and material usage. For example, increasing the number of layers can increase assembly complexity and error rates, while choosing a more expensive substrate like Rogers or ceramic material will drive up production costs.

Another important aspect to consider is the type of components used in the design. For instance, through-hole parts require drilled holes in the PCB, which drives up fabrication and assembly costs because of the extra hand soldering work involved. By contrast, surface mount devices are much cheaper to assemble because they don’t require drilled holes in the PCB.

By minimizing the use of through-hole components in your pcb manufacturing assembly, you can significantly reduce your assembly costs. However, if you are forced to choose through-hole components, try to minimize their size and avoid placing them near larger or taller SMT components. This will make it easier for your assembler to handle the larger components without damaging the smaller ones.

Also, try to avoid component placements that are not 0 or 90 degrees from each other, as some SMT pick and place machines can’t handle this. Additionally, keep in mind that the thickness of the PCB can impact production costs as well. Thicker boards may require more holes, which can lead to higher assembly costs. In addition, it is always best to panelize the boards whenever possible because it will save both fabrication and assembly time.

How to Reduce the Cost of Pcb Manufacturing Assembly

During the pre-production design phase, it is also important to review the part placements in the schematics to ensure they are accurate. Incorrect footprints for integrated components can cause issues during the fabrication process, such as uneven heat distribution across the component and incorrect mounting of the component. This can result in additional reworking and testing costs.

When purchasing the components for your PCBs, try to buy them in large quantities to reduce unit prices through economies of scale. This is especially true for the first run, which can be costly because of setup charges and other one-time fees. Wave soldering is highly efficient for mass production due to its capability to solder many joints simultaneously. It is particularly useful for double-sided PCBs where through-hole components are prevalent.

Finally, try to stay away from short turnaround times, as they can drive up assembly pricing by forcing companies to put other orders on hold and expedite shipping. Instead, try to find a manufacturer that offers a wide range of turnaround options with slower alternatives for those who cannot wait days or weeks for their order. This will help you save money while still ensuring high-quality products for your customers.

Reflow soldering is favored for its precision and suitability for high-density PCB assemblies with intricate SMT components. It allows for multiple reflows, enabling complex, multi-layered PCBs to be manufactured with high reliability.

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