Printed Circuit Boards (PCBs) are the backbone of almost all modern electronic devices. From smartphones to medical devices, PCs, and industrial machinery. PCBs are integral to a wide array of products. However, designing and manufacturing PCBs can be expensive, especially for companies working on tight budgets or launching new products.
The good news is that there are several ways of reducing PCB design costs without sacrificing quality. In this blog, we’ll explore actionable tips and strategies that can help you optimize your design process and make cost-effective decisions without compromising on the performance or reliability of your PCBs.
Average PCB Design Cost in 2024
Here’s a table summarizing the average PCB design costs in 2024 based on various factors:
| Design Stage | Average Cost | Notes |
| PCB Design | $5,000 – $10,000 | Includes schematic design, component placement, and layout optimization. Costs vary by complexity. |
| PCB Prototyping | $1,000 – $2,500/iteration | Real-world testing phase; costs depend on board size and layers |
| Advanced Design Features | Additional $1,000+ | Features like high-density interconnects (HDI) or multi-layer designs increase costs, |
| Hourly Rates | $90 – $145/hour | Rates for PCB design services vary by provider and region. |
These costs depend significantly on the board’s complexity, size, and the inclusion of advanced features like high-speed routing or specific material requirements.
Key Tips for Reducing PCB Design Costs Without Cutting Corner
Reducing PCB design costs is possible with a few smart strategies. These simple steps can help you cut costs while making sure your PCB meets the required performance and reliability standards.
Worried About Production Cost? Here is Our Detailed Blog About Reducing Production Cost
1. Start with a Clear Design Plan
One of the most effective ways to reduce PCB design costs is by starting with a well-defined design plan. When designing a PCB, having a clear understanding of the components, functions, and layout can prevent costly mistakes and rework. Here’s how a good plan can save you money:
Prevention of Design Errors:
A well-thought-out plan ensures that your PCB design is functional from the get-go, this reduces the chances of multiple revisions.
Reduced Iterations:
With a solid design plan, you can avoid unnecessary changes during the design process, which can add to both time and cost.
Make sure to carefully consider all aspects of the design, such as the size, shape, and number of layers, before starting. Having a complete understanding of your PCB’s requirements will help you make informed decisions throughout the process. Good planning is one of the best tips to save money on PCB design, as it helps you avoid wasting expensive materials and components.
Also Read: Click Here to Know the Best Prototyping Practices
2. Use Standard Components
One of the easiest ways to reduce PCB design costs is by using standard components. Custom parts may offer unique functionality, but they often come with higher costs due to manufacturing processes, limited availability, or additional design time.
Availability and Price:
Standard components, such as resistors, capacitors, and transistors, are widely available and come at a fraction of the price of custom components.
Simplified Sourcing:
Using common components makes it easier to find suppliers and ensures better lead times.
When possible, opt for off-the-shelf components instead of custom ones. Additionally, look for components that have long-term availability to avoid sourcing issues down the road. This approach contributes directly to reducing cost and helps with making the boards as simple as possible, without unnecessary complexity.
3. Optimize PCB Size and Layers
The size and complexity of a PCB can significantly impact its cost. Larger and more complex designs typically require more time and resources to manufacture. This may result in higher costs.
If you make thoughtful decisions about the size and layers of your PCB, you can significantly reduce costs while maintaining the required functionality. Remember, reducing material expenses is crucial when managing your budget, so ensure you’re not overspending on unnecessary features or extra layers.
However here are a few strategies to minimize size and layers:
Minimize Board Size:
Smaller PCBs require fewer materials and reduce manufacturing costs. Therefore focus on creating a compact design that meets the requirements without unnecessary space or features.
Reduce Layer Count:
Multi-layer boards cost more due to the additional layers of material and complexity in manufacturing. If your design can work with fewer layers, you’ll cut down on both material costs and production time.
Use Efficient Routing:
Proper routing ensures that you can fit components into a smaller area, this reduces the overall size of the PCB and the number of layers needed.
Major Differences Between MVP vs. Prototype
4. Design for Manufacturability (DFM)
Design for Manufacturability (DFM) is a strategy that helps make sure your PCB design is easy and affordable to produce. When you follow DFM guidelines, you can avoid costly mistakes and simplify the manufacturing process. This approach is a great way of reducing PCB design costs while ensuring your design is efficient and effective.
Keep Trace Widths and Spacings Consistent:
Keeping trace widths and spacings standard ensures that your PCB is easier and cheaper to manufacture. Some manufacturers may charge extra if your design has non-standard trace widths or other unique requirements.
Avoid Complex Shapes and Cuts:
Complex shapes and cuts can be challenging to manufacture, leading to additional costs. Stick to simpler, more common shapes and designs.
Design for Assembly:
Ensure that your PCB is easy to assemble by following best practices in component placement and orientation. The easier the PCB is to assemble, the lower the assembly costs will be.
5. Use PCB Design Software Effectively
The right PCB design software can help you save both time and money. Most modern PCB design tools come with powerful features that can help streamline the design process and prevent costly errors.
Here’s how you can maximize the use of these tools:
Automated Error Checking:
Most PCB design software includes error-checking features that can detect potential design issues, such as trace width violations or component overlap. When you catch these issues early, it can save you time and money in the prototyping and manufacturing stages.
Design Libraries:
Many software tools offer built-in design libraries with pre-approved components. Using these libraries can save time in sourcing parts and ensure that you’re working with cost-effective components.
Simulation Tools:
Affordable PCB design tools often include simulation capabilities, and allow you to test your design virtually before it’s produced. This helps identify potential issues with signal integrity, power distribution, and component interaction, all of which can be expensive to fix once the PCB is manufactured.
6. Prototype Before Full-Scale Production
It’s always a good idea to prototype your PCB design before moving to full-scale production. Prototyping allows you to test your design in real-world conditions, and ensure that it meets your requirements and functions as intended.
Catch Errors Early:
Prototyping can help identify design flaws, poor component choices, or other issues that may not have been obvious in the digital design phase.
Reduce Costs in the Long Run:
While prototyping may involve some upfront costs, it can save you significant money by preventing expensive mistakes during full-scale production.
Additionally, make sure to build a functional prototype and test it thoroughly before proceeding with mass manufacturing. This way, you can be confident in the design and avoid costly revisions later on.
7. Choose the Right PCB Manufacturer
Choosing the right PCB manufacturer can have a significant impact on your overall costs. Different manufacturers offer varying levels of service, quality, and pricing. Here are some tips to choose the right one:
Get Multiple Quotes:
Don’t settle for the first quote you receive. It’s important to compare pricing from multiple manufacturers to find the best balance between cost and quality.
Consider Location:
Domestic manufacturers may charge more than overseas manufacturers, but they offer faster lead times and lower shipping costs. Consider your time-to-market and total expenses when choosing your manufacturer.
Evaluate Quality Control:
A manufacturer that offers consistent quality control will reduce the chances of defects and costly rework. Therefore, ensure the manufacturer you choose has a strong track record of quality assurance.
8. Reduce Testing and Rework Costs
Testing is a critical part of the PCB design process, but excessive testing and rework can drive up costs. Efficient testing practices can help ensure quality while keeping costs down. To minimize these expenses, consider:
Automating Testing:
Automated testing methods can help you check your PCBs more efficiently, this reduces labor costs and the chances of human error.
Test in Batches:
Testing PCBs in batches can reduce testing time and costs. Testing a small sample of your PCBs can be enough to confirm that the manufacturing process is working as expected.
9. Keep Communication Clear with Your Team and Suppliers
Clear communication is important to keep costs down in any project. When everyone, your design team, suppliers, and manufacturers, is on the same page, you can avoid mistakes or delays that could increase costs. This is especially helpful when reducing PCB design costs, as it ensures smooth and efficient work throughout the process.
Frequent Updates:
Keep your team and suppliers informed throughout the design process to avoid any last-minute changes.
Collaborate on Design Decisions:
Work closely with your manufacturers early on to ensure that your design is optimized for cost-effective production.
How Can Cygnus Corp Help You Cut Costs in PCB Design Without Compromising Quality?
At Cygnus Electronic Corporation, we specialize in providing cost-effective PCB design solutions that don’t compromise on quality. Whether you’re looking to reduce material expenses or optimize your PCB layout, we work closely with our clients to ensure every design is both functional and affordable.
As your trusted PCB design partner, we offer expertise in reducing PCB design costs through smart design decisions, use of standard components, and efficient manufacturing techniques. Our team is here to guide you in creating PCBs that are simple yet powerful, and ensure that your product meets your needs while staying within budget.
Contact Cygnus Electronic Corporation today to learn more about how we can help you
FAQs
Why is my PCB so expensive?
Your PCB might be expensive due to factors like complex design, high-quality materials, low production volume, or specific manufacturing requirements. Simplifying the design and ordering in bulk can help lower costs.
How can I improve my PCB design?
Improving your PCB design involves careful planning, choosing cost-effective components, and ensuring good design practices like reducing layer count and minimizing routing complexity.
Which things affect the cost of PCB?
The cost of PCB is affected by factors like design complexity, material quality, production volume, layer count, and the number of components used.
Where can I find affordable PCB manufacturing services in Canada?
You can find affordable PCB manufacturing services in Canada through companies like Cygnus Electronics. We offer reliable and cost-effective solutions for designing and manufacturing PCBs, and ensure quality while keeping costs low.
