In the development of electronic products, printed circuit boards (PCBs) are an indispensable component, while PCBA (PCB Assembly) represents the finished product after PCB assembly. Whether you're an individual, a company, or a large enterprise, understanding the cost structure of PCB manufacturing and production is crucial. Below, we explore how much PCB manufacturing costs.
1. Substrate Cost
The foundation of a PCB is its substrate, with common material types including FR4, CEM-1, and aluminum-based boards. Different substrate types vary significantly in price. For example, FR4 substrates are widely favored for their excellent electrical and processing performance, but their prices are affected by fluctuations in the prices of raw materials such as international copper prices, epoxy resin, and fiberglass cloth. Aluminum-based boards, on the other hand, are highly valued in certain applications due to their superior heat dissipation, but they are typically more expensive than FR4 substrates.
1. Board Size and Layer Count
- Single-layer board: The simplest structure, lowest cost
- Double-layer board: The most common type, cost-effective
- 4-layer board and above: Each additional layer significantly increases cost
- Pricing is usually calculated per square centimeter per layer
2. Substrate Material
- FR-4 (Fiberglass epoxy): Standard choice, economical
- High-frequency materials (e.g., Rogers): Used in RF circuits, expensive
- Aluminum-based boards: Commonly used in LED lighting, good heat dissipation, higher cost
- Flexible PCBs: Special applications, 2-5 times more expensive than rigid boards
2. Manufacturing Process Costs
The PCB manufacturing process involves multiple production steps, such as inner layer circuit fabrication, lamination, drilling, plating, outer layer circuit fabrication, solder mask application, silkscreen printing, and surface finishing (e.g., HASL, ENIG, OSP, carbon ink). Each step requires specialized equipment and skilled operators, contributing to the overall cost. In particular, processes like drilling and plating incur additional costs based on the number of holes, plating area, and thickness.
1. Production Process Requirements
- Minimum trace width/spacing: Finer traces increase cost (e.g., 0.2mm is more expensive than 0.3mm)
- Hole size: Smaller holes (<0.3mm) increase cost
- Surface finish: Leaded HASL is the cheapest, while ENIG and immersion gold are more expensive
- Special processes: Impedance control, blind/buried vias, etc., significantly increase costs
2. Order Quantity
- Prototyping (1-10 pieces): High unit cost, but low total cost
- Small batch (50-500 pieces): Unit cost decreases significantly
- Large batch (1000+ pieces): Best unit pricing
3. Lead Time
- Standard delivery (5-7 days): Normal pricing
- Expedited (48-72 hours): 30%-100% additional fee
- Urgent (24 hours): Price may double
3. PCB Price Range Reference (For Reference Only, Actual Quotes May Vary)
1. Prototyping Prices (For 5 Pieces)
| Type | Size (Within 10x10cm) | Price Range (CNY) |
|---|---|---|
| Single-layer | Standard process | 50-100 RMB |
| Double-layer | Standard process | 100-200 RMB |
| 4-layer | Standard process | 400-800 RMB |
| 6-layer | Standard process | 800-1500 RMB |
| Aluminum-based | Single-layer | 200-400 RMB |
2. Small-Batch Prices (For 100 Pieces)
| Type | Size (10x10cm) | Price Range (RMB/piece) |
|---|---|---|
| Double-layer | Standard process | 2-5 RMB |
| 4-layer | Standard process | 15-30 RMB |
| 6-layer | Standard process | 40-80 RMB |
If customers require special designs or modifications, PCB manufacturers may charge additional design fees. Other costs, such as packaging, shipping, and taxes, should also be considered.
3. Special Process Additional Fees
- Impedance control: +20%-50%
- ENIG (Immersion gold): +100-300 RMB per square meter
- Blind/buried vias: +30%-100%
- Edge chamfering: +5%-10%
4. Testing Costs
After manufacturing, PCBs must undergo a series of tests to ensure quality. These include electrical performance tests (e.g., continuity, insulation), reliability tests (e.g., thermal shock, vibration), and visual inspections.
5. How to Reduce PCB Manufacturing Costs?
- Optimize design: Use standard hole sizes and trace widths to minimize special process requirements.
- Panelization: Combine multiple small PCBs into a single panel to share engineering costs.
- Choose the right supplier: Compare quotes and services from different manufacturers.
- Avoid rush orders: Allow sufficient production time.
- Bulk ordering: Place larger orders to secure discounts.
6. PCB Cost Calculation Example
Case: Double-sided FR4 board, 8x10cm, standard process, green solder mask with white silkscreen, leaded HASL, 5 pieces.
- Substrate cost: 8x10 = 80 cm², at 0.03 RMB/cm² → 2.4 RMB/piece
- Engineering fee: 100 RMB (fixed)
- Film fee: 50 RMB (fixed)
- Total cost: (2.4 x 5) + 100 + 50 = 162 RMB
Same board for 100 pieces:
- Engineering fee amortized: ~1 RMB/piece
- Total cost: (2.4 + 1) x 100 = 340 RMB (unit cost drops to 3.4 RMB/piece)
7. PCB Budgeting Recommendations
- Prototyping phase: Allocate 500-2000 RMB (depending on complexity).
- Small-batch production: Estimate based on board area—2-8 RMB/piece for double-layer, 15-40 RMB/piece for 4-layer.
- Include a 10%-20% buffer for design changes or process adjustments.
In summary, PCB manufacturing costs consist of multiple factors, including substrate costs, process fees, testing expenses, and additional overhead. These costs are influenced by various factors such as substrate type, process complexity, testing requirements, and customer needs. Therefore, it is difficult to provide a fixed cost figure. If you have PCB manufacturing needs, we recommend consulting with a professional PCB manufacturer for detailed quotes. An excellent PCB manufacturer (such as Topfast) not only provides high-quality products and services but also offers expert advice and support throughout the project, helping you successfully complete your electronic product design and manufacturing.