Introduction to PCB Manufacturing
Printed circuit boards (PCBs) are essential components in nearly all modern electronics. PCBs provide the foundation to mount and connect electronic components using conductive copper traces etched from copper sheets laminated onto a non-conductive substrate.
While PCB fabrication requires extensive expertise and expensive equipment, the proliferation of consumer electronics has created a market for affordable PCB prototype and small-batch manufacturing accessible to hobbyists, makers, and engineers. This guide explores selecting a PCB manufacturer optimized for prototyping or small production runs from ten to a few hundred boards.
Overview of the PCB Manufacturing Process
PCB fabrication is a complex, multi-step process that can be summarized into three main stages:
- Design – Create schematics and layout using CAD software. This stage determines the board size, layer count, component placements, and trace routing.
- Manufacturing – Convert design files into production using processes like etching, drilling, plating, printing and lamination to produce finished PCBs.
- Assembly – Install and solder components onto fabricated PCBs. Some PCB services offer assembly and component sourcing.
While PCB fabs handle manufacturing, most also provide design rule checks, file conversions, and other services to support customers and ensure manufacturability.
Factors to Consider When Selecting a PCB Manufacturer
With numerous domestic and overseas PCB manufacturers competing for prototyping and short-run business, it’s crucial to weigh key factors when selecting a PCB supplier:
Location
For very urgent deliveries or complicated projects requiring close collaboration, a domestic PCB manufacturer may be preferable. For standard boards, overseas suppliers offer substantially lower costs, though at the expense of longer lead times.
Quality
Verify the maker uses modern manufacturing equipment and processes. Evaluate minimum trace/space widths, layer alignment tolerances, solder mask quality, and other features that affect board performance.
Services
Determine if the company provides value-added services like assembly, component sourcing, and design for manufacturing (DFM) checks that save time and hassles.
Cost
Weigh unit pricing, lot charges, shipping fees, and inclusion of features like solder mask, silkscreening, and gold plating when comparing budgetary quotes. Consider total cost for your specific project and order quantity.
Lead Times
Rapid-turnaround under 5 days is ideal for prototyping, while production orders may allow 2-3 weeks for fabrication. Confirm standard and expedited service options and costs.
Customer Service
Look for reviews highlighting customer experiences. Clear communication and technical expertise from sales staff indicate how well the company supports its customers.
Top PCB Manufacturers for Hobbyists and Prototyping
To simplify the supplier selection process, we’ve profiled ten top manufacturers optimized for low volume orders from independent inventors, hobbyists, and engineers:
1. JLCPCB
- Location: China
- Quality: Good, 2 layer 1 oz copper, 4 mil min trace/space
- Services: SMT assembly
- Cost: Very low, $2 per sq in, free shipping
- Lead Times: 24 hrs (expedited), 2 days (standard)
- Customer Service: Excellent
JLCPCB has earned a reputation for affordable, quick-turn PCBs thanks to transparent pricing, intuitive online tools, and reliable quality. While unable to match domestic service, they’re highly competitive internatinoally. JLCPCB excels at low complexity boards requiring fast delivery on a tight budget.
2. PCBWay
- Location: China
- Quality: Good, multilayer options, 3 mil min trace/space
- Services: Assembly, component procurement
- Cost: Very low, $2.50 per sq in, free shipping
- Lead Times: 24 hrs (expedited), 2 days (standard)
- Customer Service: Excellent
PCBWay has expanded from a specialist in LCP/flex PCBs to become a leading budget PCB maker thanks to great service and reliable quality. Along with cost-effective standard PCBs, they offer appealing options like free SMT assembly, impedance-controlled boards, and flexible PCB manufacturing.
3. OSH Park
- Location: USA
- Quality: Excellent, ENIG surface finish, 8 layer support
- Services: Open source community engagement
- Cost: Higher, $5 per sq in, free domestic shipping
- Lead Times: 1 week (standard)
- Customer Service: Very good
While costing more than international services, OSH Park justifies premium pricing by focusing on superlative quality, transparency, and supporting open-source projects/community. With consistently excellent results, US location, and personal customer service, they’re ideal for complex or mission-critical hobbyist boards.
4. Seeed Studio
- Location: China
- Quality: Good, 2 layer boards
- Services: Assembly, components, OEM
- Cost: Low, $10 per sq in, free shipping
- Lead Times: 1 week (standard)
- Customer Service: Good
Seeed Studio provides integrated manufacturing of PCBs, assembly, and components for prototypes or high-mix/low-volume production. While lacking the rock-bottom pricing or rapid turnarounds of other Chinese manufacturers, Seeed simplifies support for complete ready-to-build PCB products.
5. Advanced Circuits
- Location: USA
- Quality: Excellent, 4 mil min features, 8 layers
- Services: DFM, assembly
- Cost: Moderate, $33 per sq in
- Lead Times: 3 days (expedited), 8 days (standard)
- Customer Service: Good
For customers requiring domestic manufacturing with fast delivery of intricate multilayer boards, Advanced Circuits combines competitive pricing and top-notch quality. While not the cheapest service, they hit the sweet spot on value for US-based prototyping.
6. ALLPCB
- Location: China
- Quality: Good, 2 oz copper, 5 mil min features
- Services: Assembly, components
- Cost: Low, $2.50 per sq in, $40 setup
- Lead Times: 24 hrs (expedited), 5 days (standard)
- Customer Service: Good
ALLPCB delivers low-cost PCB production thanks to high automation and economies of scale. With a $2.50 per square inch fabricaiton cost and $40 low setup fee, they appeal to hobbyists needing medium quantities of simple boards. Assembly and component services provide added value.
7. Eurocircuits
- Location: Europe
- Quality: Excellent, 4 mil min features, 6 layers
- Services: DFM, assembly, components
- Cost: Moderate, $50 per sq in
- Lead Times: 24 hrs (expedited), 8 days (standard)
- Customer Service: Excellent
For hobbyists looking for top service and quality without overseas lead times, Eurocircuits hits a nice balance. Their excellent quality, tranparent pricing, and strong customer support justify moderately higher pricing for customers needing boards faster than Asian suppliers can deliver.
8. Sunstone Circuits
- Location: USA
- Quality: Excellent, 4 mil min features, 8 layer
- Services: DFM, assembly
- Cost: $59 per sq in (2 layer)
- Lead Times: 48 hrs (expedited), 8 days (standard)
- Customer Service: Very Good
Sunstone Circuits focuses exclusively on fast-turnaround prototypes thanks to an automated and optimized process allowing 48 hour expedited delivery of high reliability boards, though with premium pricing. Their friendly and expert staff provide design support and pre-order reviews.
9. Aisler
- Location: Germany
- Quality: Good, 1oz copper, 5 mil min features
- Services: Small assemblies
- Cost: €49 per sq in (approx $50), €19 setup
- Lead Times: 24 hrs (expedited), 8 days (standard)
- Customer Service: Good
Aisler provides a nice European-based option for hobbyists wanting good quality boards with fast delivery, though not matching top Chinese vendors on pricing. Their web-based tools simplify ordering small to medium quantities of boards requiring basic assembly.
10. DirtyPCBs
- Location: USA
- Quality: Fair, 8 mil min features
- Services: None
- Cost: Low, $5 per sq in
- Lead Times: 15 days (standard)
- Customer Service: Mediocre
As the name implies, DirtyPCBs focuses more on low cost than perfect quality. With relaxed design rules and fabrication imperfections expected, they appeal when bottom-dollar pricing trumps cosmetic flaws for hobby boards ordered in small lots.
PCB Design and File Preparation Tips
To maximize manufacturability and avoid issues during PCB fabrication, follow these design practices:
- Follow manufacturer design rules and use their design rule check tools
- Allow adequate clearance between traces and board edges
- Minimize trace length variations between matched-length signals
- Include complete placement for both top and bottom layers
- Supply both gerbers and original source files (SCH, PCB, etc)
- Perform a thorough design review before ordering boards
With attention to manufacturability during planning and design reviews, even hobbyists can achieve success with affordable PCB prototype services catering to low volume orders.
Frequently Asked Questions
Q: How many PCBs can I order as a hobbyist?
Most manufacturers have order minimums of just 5 or 10 boards. Maximum quantities also vary, but usually range from 100-1000 boards. If needing higher volumes, contact the company to discuss manufacturing capabilities.
Q: How long does PCB manufacturing take?
Standard lead times range from 5 days to a few weeks. Expedited services with 24-48 hour lead times are available from some manufacturers, but cost extra. Confirm specific lead times when requesting PCB quotes.
Q: Can I get assembled PCBs as a hobbyist?
Many manufacturers offer PCB assembly for prototypes or small batches, though some only support assembly for mid-to-high volume production. Assembly costs extra, but saves the effort of soldering boards yourself.
Q: What design software should I use?
Many options exist ranging from free to expensive professional packages. KiCAD, Eagle, and OrCAD are popular picks for hobbyists. Use software capable of outputting standard Gerber and drill files compatible with your PCB manufacturer.
Q: Can hobbyists make multilayer boards?
While more complex, some manufacturers offer 2 to 8 layer boards for hobbyists at reasonable costs. Just ensure your PCB software can design multilayer boards and budget additional cost over 2-layer designs.
Conclusion
Selecting an appropriate PCB manufacturer optimized for low volume prototyping or hobbyist projects need not be intimidating or expensive. Thanks to competition and technology advances, even hobbyists can inexpensively fabricate quality PCBs with fast lead times by selecting a supplier catering to short run demands. With attention to manufacturability, you can successfully turn your own PCB designs into reality.
0 Comments