PCB Fabrication Assembly
The cost of pcb fabrication assembly depends on the number of components, board size, and design complexity. The assembly process uses various automation equipment including a pick and place machine, reflow oven, wave soldering, AOI and first-article inspection machines, and X-ray testing machines. The final price also depends on the geographical location of the manufacturing site and labor costs which vary based on going rates, facility expenses and overhead.
The PCB design for manufacturing stage can be conducted using a wide variety of software including Altium Designer, KiCad, EasyEDA, and PADS to name a few. Once the design is complete, it will be sent to a PCB contract manufacturer (CM) who will perform a series of checks to ensure that the PCB meets all the technical requirements for assembly. They will then order the raw circuit boards from a fabrication vendor using Gerber data that has been verified by their internal quality team.
Depending on the project, the CM may choose to use rigid FR-4 material or flexible polyimide for the base of the PCB. Rigid-flex designs typically feature a hybrid of the two types of substrates. The choice of materials will affect copper usage and assembly costs.
As the name suggests, flex PCBs can be bent and folded to fit into tight spaces which can reduce space utilization and overall product dimensions. They are also able to withstand mechanical stress and vibrations which can improve reliability in harsh environments.
Cost of PCB Fabrication Assembly
However, the flexibility of a flex circuit board comes at a cost in terms of assembly time and assembly costs which can make it more expensive than a comparable rigid PCB. As the board is bent and flexed, it is more difficult to position components correctly. In addition, the proximity of signals to the bend region can impact signal integrity and electromagnetic interference (EMI).
Another factor that contributes to a PCB’s assembly cost is the number of connectors and cables that will be required. Multiple connections can lead to solder and other assembly associated failures. This is especially true in high-reliability applications. Rigid-flex circuit boards can eliminate the need for additional connectors by providing a solution that integrates the components into the board itself.
The cost of pcb fabrication assembly also depends on the type of components used in the design. Surface mount technology (SMT) is typically cheaper than through-hole components as the setup costs are lower and the assembly process can be automated. However, SMT is not suitable for all applications and it can result in short-circuiting or other quality issues which will require manual rework.
Finally, the final cost of a PCB depends on its geographical location and labor costs which can vary drastically based on going rates, facility expenses and other factors. Generally, manufacturing costs are higher in North America and Western Europe than Asia where the labor rates are substantially less. This can add up to a significant amount of money when the number of assemblies is high.
