Factors that affect PCB Cost
Before diving into specific numbers, it’s important to understand the main variables that influence the cost of manufacturing a PCB:
Board size
The physical dimensions of the PCB have a significant impact on cost. Larger boards require more material and take longer to manufacture, thus increasing the price. PCBs are typically priced per square inch, so even a small increase in size can noticeably affect the total cost.
Number of layers
PCBs can be made with anywhere from one to dozens of conductive layers. Simple boards may only need a single layer, while complex designs often require four or more layers to accommodate all the necessary connections. Each additional layer adds to the material and manufacturing costs.
Quantity
As with most products, ordering PCBs in higher quantities generally results in a lower per-unit cost. This is because the fixed costs associated with setting up the manufacturing process are spread out over a larger number of boards. However, for small-scale projects or prototypes, ordering just a few boards is often more practical and economical.
Material type
The most common base material for PCBs is FR-4, a glass-reinforced epoxy laminate. However, other materials like polyimide, ceramic, or metal can be used for specialized applications. These alternative materials tend to be more expensive than standard FR-4.
Surface finish
The exposed copper traces on a PCB are typically coated with a protective surface finish to prevent oxidation and improve solderability. Common finishes include hot air solder leveling (HASL), immersion silver, immersion tin, and gold plating. Each type of finish has a different cost associated with it.
Minimum feature size
The minimum width of the traces and spacing between them is known as the feature size. Smaller feature sizes allow for denser, more complex designs but also require more precise manufacturing processes. As a result, PCBs with very fine features tend to be more expensive than those with larger traces and spaces.
PCB fabrication costs
Now that we’ve covered the main factors influencing PCB cost, let’s look at some actual prices from popular fabrication services. Note that these prices are for standard FR-4 material and do not include shipping or taxes.
OSH Park
OSH Park is a community-driven PCB fabrication service known for its distinctive purple soldermask. They offer a fixed price of $5 per square inch for two-layer boards, with a minimum order of three boards. For example, a 2″ x 3″ board would cost $30 for a set of three.
| Board Size | Quantity | Price per Board | Total Cost |
|---|---|---|---|
| 1″ x 1″ | 3 | $1.67 | $5 |
| 2″ x 2″ | 3 | $6.67 | $20 |
| 2″ x 3″ | 3 | $10 | $30 |
| 3″ x 3″ | 3 | $15 | $45 |
OSH Park also offers four-layer boards at $10 per square inch and six-layer boards at $15 per square inch, with the same three-board minimum order.
JLCPCB
JLCPCB is a Chinese PCB manufacturer that offers very competitive prices for a wide range of board specifications. Their pricing is based on the board size, number of layers, and quantity ordered. For example, here are some prices for two-layer boards with a lead time of 3-5 days:
| Board Size | Quantity | Price per Board | Total Cost |
|---|---|---|---|
| 1″ x 1″ | 5 | $2 | $2 ($2 setup fee) |
| 2″ x 2″ | 5 | $2 | $10 |
| 2″ x 3″ | 5 | $2.40 | $12 |
| 3″ x 3″ | 5 | $3.60 | $18 |
| 1″ x 1″ | 100 | $0.80 | $80 |
| 2″ x 2″ | 100 | $0.80 | $80 |
| 2″ x 3″ | 100 | $0.96 | $96 |
| 3″ x 3″ | 100 | $1.44 | $144 |
JLCPCB also offers four-layer and six-layer boards at slightly higher prices, as well as various surface finish options and expedited manufacturing for an additional cost.
PCBWay
PCBWay is another popular Chinese PCB manufacturer with a wide range of fabrication options. Like JLCPCB, their pricing is based on board size, number of layers, and quantity. Here are some example prices for two-layer boards with a standard lead time:
| Board Size | Quantity | Price per Board | Total Cost |
|---|---|---|---|
| 1″ x 1″ | 5 | $5 | $25 |
| 2″ x 2″ | 5 | $5 | $25 |
| 2″ x 3″ | 5 | $5 | $25 |
| 3″ x 3″ | 5 | $5 | $25 |
| 1″ x 1″ | 100 | $0.60 | $60 |
| 2″ x 2″ | 100 | $0.60 | $60 |
| 2″ x 3″ | 100 | $0.90 | $90 |
| 3″ x 3″ | 100 | $1.35 | $135 |
PCBWay offers a variety of additional services, such as expedited manufacturing, PCB assembly, and stencil fabrication, for additional fees.
Other costs to consider
In addition to the base PCB fabrication cost, there are a few other expenses to keep in mind when making your own circuit boards:
Design software
To create the PCB layout and generate the necessary manufacturing files, you’ll need to use electronic design automation (EDA) software. Some popular options include KiCad (free and open-source), EAGLE (free for non-commercial use, paid licenses available), and Altium Designer (paid, professional-grade). Prices for paid software can range from a few hundred to several thousand dollars, depending on the features and license type.
Components
Of course, a bare PCB isn’t much use without electronic components to populate it. The cost of components can vary widely depending on the specific parts needed and the quantity purchased. Common passive components like resistors and capacitors are generally inexpensive, while specialized ICs, sensors, or connectors can be more costly. It’s a good idea to factor in the cost of components when budgeting for your PCB project.
Assembly
If you’re comfortable with soldering, you can assemble the PCB yourself and save on labor costs. However, for complex boards or large quantities, it may be more efficient to use a professional assembly service. PCB assembly prices depend on the number and type of components, the complexity of the board, and the quantity being assembled. Some fabrication services, like PCBWay, offer turnkey assembly solutions that can streamline the process.
Frequently Asked Questions (FAQ)
1. Can I make a PCB at home without using a fabrication service?
Yes, it is possible to make simple PCBs at home using methods like toner transfer or UV exposure. However, these DIY techniques are generally limited to single-layer boards and may not produce results as professional or reliable as commercial fabrication services.
2. How long does it take to receive PCBs from a fabrication service?
The lead time for PCB fabrication varies depending on the service and the specific options chosen. Standard lead times are typically 1-2 weeks, but many services offer expedited manufacturing for an additional cost, with turnaround times as short as 24-72 hours.
3. What is the minimum quantity of PCBs I can order from a fabrication service?
Minimum order quantities vary by service, but many offer low-quantity options for prototyping or small projects. For example, OSH Park has a minimum order of three boards, while JLCPCB and PCBWay allow orders as small as five boards.
4. Can I get a discount for ordering a larger quantity of PCBs?
Yes, most fabrication services offer volume discounts for larger orders. The specific discount structure varies by service, but in general, the per-unit cost decreases as the quantity increases.
5. Are there any additional fees or charges beyond the base PCB fabrication cost?
Some services may charge additional fees for things like setup, tooling, or stencil creation. Shipping costs and taxes (if applicable) are also typically not included in the base PCB fabrication price. Be sure to review the pricing details carefully and account for any additional charges when budgeting for your project.
In conclusion, the cost of making your own PCB can range from a few dollars to several hundred dollars or more, depending on the size, complexity, and quantity of the boards being manufactured. By understanding the various factors that influence PCB cost and comparing prices from different fabrication services, you can find the most cost-effective solution for your project’s needs.
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