Things to Consider when Buying Printed Circuit Boards

Before placing an order, there are several factors to weigh when purchasing circuit boards. Start by confirming whether the manufacturer provides options for short runs or standard sizes. This flexibility can help you save costs by allowing you to buy a small quantity instead of investing in a large batch of custom boards if you only need one or two.

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The first step is to have a clear circuit design and schematic in place; a circuit board serves little purpose without an underlying circuit. Numerous free tools are available that can assist you in creating your schematic, so it’s advisable to choose one that offers simulation capabilities. Prototype your design to confirm functionality before proceeding with a bulk order, as a good board won't compensate for a flawed circuit design.

Once your schematic is validated and you have a working prototype, it's time to design the printed circuit board itself.

This phase requires considerable time and knowledge of how track routing influences circuit performance. However, for simpler designs, the process may be relatively straightforward. Many manufacturers provide their own design software, so check their websites for software downloads and user guides.

Since you’ll likely order one of their standard-sized boards, ensure that your design project adheres to those dimensions to avoid being classified as a custom job, which may incur additional costs.

Using design software has the added benefit of generating output files in the standardized Gerber file format, which plotters use to print tracks on the boards. Ensure that the tool you opt for has an option to export your design to this format.

Double-check your design, prototype, and board layout diligently, as errors in this stage can lead to expensive reorders. Once everything checks out, select your desired boards, upload the Gerber file, and proceed with payment.

Upon receiving your boards, inspect them for manufacturing defects and any shipping damage, such as incomplete tracks or un-drilled holes. Conducting this inspection before soldering the parts allows for a quick replacement if defects are found, ultimately saving you the cost of going back and desoldering components.

Final Thoughts
With your boards verified and tested, you can begin assembling your circuit. Assuming your previous checks were thorough, your circuit should function correctly.

Having your project encapsulated in a printed circuit board not only adds a level of professionalism but can also enhance its visual appeal, especially in complex designs.

Wishing you the best of luck with your projects, and enjoy the process of creating electronic circuits!

A significant portion of the costs associated with PCB assembly relates to non-recurring engineering (NRE). Manufacturers must prepare their equipment for production, regardless of whether you request one unit or ten thousand. Depending on the complexity and component choices, they may opt for hand assembly or even selective soldering to streamline production.

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Be mindful that the board manufacturer may need to allocate specific equipment to accommodate a single board run, especially if that equipment was part of a more lucrative larger job. This often results in adjusted pricing to make the operation worthwhile for them.

As you increase your order quantities, the unit cost will generally decrease as NRE expenses get distributed across multiple units.

Working with a reputable board house typically costs around $800 for comprehensive PCBA services. While price comparison is advisable, bear in mind that cheaper options may not always guarantee quality.

If your PCB requirements fall within standard parameters—such as one or two layers, no complex ball grid array components, and simple rectangular shapes—there are many PCB assembly companies that offer competitive pricing (<$50, excluding component costs). Many of these companies are located in China and can produce multiple standard prototypes for diverse clients simultaneously.

If your needs are less critical regarding reliability and speed, these budget-friendly options can be worth considering.

However, for designs with specific assembly requirements—such as those exceeding two layers or involving ball grid arrays—prices can rise but typically remain within the $50 to $200 range.

While similar rapid prototyping services can be found in various countries, they may be quicker yet more expensive.

If you anticipate needing "industrial-level" production with in-depth testing, the costs for single units will escalate dramatically.

Choosing a manufacturer specializing in larger production runs may also lead to high costs for single PCB orders due to setup fees.

To summarize, for those seeking a single PCB without future large-scale orders, select manufacturers that specialize in prototyping. You can choose between inexpensive production options in China or more premium services locally.

In conclusion, if you aren’t familiar with PCB manufacturing and assembly, starting with a more affordable service can be beneficial for validating your design. Should modifications be necessary, this allows you to avoid incurring high costs. Once you're satisfied with the prototype's quality, you can then decide if it’s worth investing in a final version of better quality, keeping the prototype as a backup.

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