Why is the manufacturing cost of PCB so high?

The cost of a PCB is influenced by various factors, including size, layer count, materials, manufacturing processes, order quantity, delivery timelines, design complexity, and quality standards. Providing detailed specifications and order information when requesting a quote is essential. Additionally, selecting the right supplier and processes can help reduce costs.

Below, we analyze the factors impacting PCB pricing in detail:

1. PCB Size and Layer Count

Size: Larger PCBs require more raw materials, increasing costs. Typically, larger PCBs are more expensive than smaller ones.
Layer Count: Multilayer PCBs involve more complex manufacturing processes and require additional materials and precision, making them costlier than single-layer or double-layer PCBs.

Thickness of the PCB: The thickness impacts the device’s overall dimensions, weight, flexibility, and heat dissipation. Common PCB thicknesses include:

• 1.6mm: Standard for single- and double-sided PCBs, balancing mechanical strength, heat dissipation, and cost.
• 1.2mm: Common for double-sided and multilayer PCBs, allowing smaller profiles and lightweight designs with higher precision requirements.
• 0.8mm: Ideal for high-density designs like premium smartphones, laptops, and compact portable devices.
• 0.6mm: Used in critical applications such as small medical devices, wearables, and compact electronics.
• 2.0mm+: Found in industrial and military applications, requiring high mechanical strength for harsh environments.

2. Material Selection

Substrate Materials: Common options include FR4, CEM-1, and aluminum-based boards, each with distinct costs and properties. For instance, aluminum substrates are more expensive due to their superior thermal performance.
Copper Foil Thickness: Thick copper foil supports high-current applications but increases costs compared to thinner alternatives.

3. Manufacturing Processes

Line Precision: High-precision circuitry demands advanced equipment and stringent process control, leading to higher costs.
Surface Treatment: Surface finishes like HASL, ENIG, or OSP vary in cost and durability, affecting overall pricing.

4. Order Quantity and Delivery Time

Order Volume: Bulk production reduces per-unit costs, so larger orders typically have lower pricing per PCB.
Delivery Time: Rush orders often require expedited production, incurring additional charges. Shorter lead times generally mean higher costs.

5. Shipping Costs and Manufacturing Location

After production, the PCB must be delivered to the customer, and shipping costs depend on factors like:

• Total distance to the destination.
• Delivery speed requirements.
• Packaging materials used for protection during transit.

Since PCBs are fragile, ensuring secure packaging increases total costs. Some manufacturers, like Visionary Engineering, may offer free shipping as part of their service.

6. Other Influential Factors

Design Complexity: Intricate designs with fine traces, multiple vias, or unique layout rules can increase manufacturing costs.
Quality Standards: Higher quality requirements necessitate rigorous testing and inspection processes, further driving up expenses.