PCB Manufacturing
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- 1Order and Procurement
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- 4Inspection and Quality Control
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- Bare PCB in 8 working hours
- PCBA with components in 2 working days
- Bare PCB manufacturing
- Components sourcing
- PCB assembling
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Looking for PCB Manufacturing Services?
At OurPCB, we’ve been a trusted Printed Circuit Board manufacturer since 2007, partnering with some of the most innovative companies, especially in the USA. From component sourcing to final assembly and testing, we’re here to bring your PCBs to life with quality and precision.
What is the PCB Manufacturing Process?
The Printed Circuit Board (PCB) manufacturing process involves several steps to turn a design into a working electronic circuit board. PCBs are used in almost all electronic devices to connect components and provide support. Below is a simple overview of the main steps in PCB manufacturing:
1. Design and File Preparation
PCB manufacturing starts with the design. Engineers use software like CAD (Computer-Aided Design) to create the layout, defining where components go and how connections are made. The design is saved in a format, usually Gerber, that manufacturers use.
2. Material Selection
The base material for the PCB is chosen based on the project’s needs. Common materials include FR4, CEM-3, and Rogers. The chosen material affects the board’s durability and performance.
3. Printing the Inner Layers
The design is printed on a photosensitive film that covers a copper-laminated board. UV light exposes the circuit pattern, and the film is developed to leave the copper traces behind.
4. Etching
Excess copper is removed, leaving only the copper traces that form the circuit. This step ensures that only the desired paths for electrical connections remain.
5. Layer Alignment and Lamination
For multi-layer boards, individual layers are aligned and laminated together. The layers are pressed and heated to fuse them into a single piece.
6. Drilling
Holes for components or electrical connections are drilled into the board. The drilling process ensures that all holes are precise and correctly placed.
7. Plating and Copper Deposition
A thin layer of copper is deposited inside the drilled holes and on the board’s surface. This connects different layers of the board and prepares it for component placement.
8. Solder Mask Application
A solder mask is applied to protect the copper traces and prevent unwanted soldering. This mask is usually green but can come in other colors like black, blue, or red.
9. Silkscreen Printing
Text, labels, and symbols are printed on the board to guide the assembly of components. This helps during the assembly and future repairs.
10. Surface Finishing
A surface finish is applied to the PCB pads. Common finishes include HASL, Immersion Gold, and OSP. The finish improves the soldering process and protects the board from damage.
11. Electrical Testing
The PCB is tested to ensure it works as designed. The tests check for open circuits, shorts, and proper connections.
12. Final Inspection and Quality Control
The PCB is inspected for physical defects, such as scratches or misalignment. Quality control ensures the board meets the required standards before moving to assembly.
13. Assembly and Packaging
The board is assembled with components like resistors and capacitors, either through Surface-Mount Technology (SMT) or Through-Hole Technology (THT). After assembly, the PCB is inspected again, packed, and shipped.
At OurPCB, we focus on small to medium volume orders, offering competitive pricing for quantities from 1 to 100 square meters.
We accept four different file formats for your PCB prototype manufacturing: Gerber, .pcb, .pcbdoc, and .cam.
We perform thorough DRC checks on all client files and will notify you immediately if there’s an issue. We’ll work closely with you to make sure the files are corrected for smooth manufacturing.
PCB Manufacturing Capability Overview
Feel free to check our capability overview below, and contact us if you have any special requirements not listed. As expert PCB board maker, we deliver high-quality PCB assembly services to meet your electronic needs.
| Specification | PCB Capability |
|---|---|
| Layer Counts | 1-32 layers |
| Lead Time | Normal: 5-6 Days Expedited: 24-48Hours |
| Materials | FR4, High TG FR4，Halogen Free material,CEM-3, Rogers HF material, etc. |
| Finished Copper Thickness | 0.5-6 OZ |
| Finished Board Thickness | 0.2-6.0mm |
| Min. Line/Track Width&Space | 3mil |
| Qualifications | ISO14001:2015, ISO9001:2015, Certified IATF16949: 2016, Certified |
| Technology | On-Across Blindried Vias, Characteristic Impedance Control, Rigid-flex Board etc. |
| Solder Mask Color | green, black, blue, white, red, yellow, and matt, etc. |
| Legend/Silkscreen Color | white, yellow, black, etc. |
| Surface Treatment | HAL, Lead Free HAL, Immersion gold, OSP, Immersion tin, Immersion silver, etc. |
| Wrap and Twist | ≤0.7% |
| Other Technology | Gold finger, peelable mask, Non-across blind-buried vias, characteristic impedance control, Rigid-flex board etc. |
How Much Does PCB Manufacturing Cost?
The average cost of PCB manufacturing is $10 to $50. The price can vary based on factors such as the size of the board, the type of material used (e.g., FR4 or Rogers), and the production labor costs involved, including time and effort. Interestingly, smaller boards can sometimes be more expensive, like in the case of a smartphone PCB, which is costly due to the complexity of the work. In contrast, larger boards may require less effort, so size doesn’t always directly impact the price. To learn more about our PCB Manufacturing cost, visit our PCB Cost Estimator page.
PCB Assembly Fabrication Techniques
Surface Mount Technology (SMT)
SMT is a widely used assembly technique where components are mounted directly onto the surface of the PCB. This method is ideal for high-density designs and offers benefits such as reduced size and weight.
Through-Hole Technology (THT)
THT involves inserting component leads into pre-drilled holes and soldering them onto the opposite side of the PCB. While bulkier than SMT, THT provides strong mechanical bonds and is often used in applications where durability is a priority.
Mixed Technology Assembly
Some complex PCBs require a combination of SMT and THT, known as mixed technology assembly. This approach allows designers to leverage the strengths of both methods, depending on the specific needs of the project.
Soldering Methods
Two common soldering methods are used in PCB assembly: wave soldering and reflow soldering. Wave soldering is typically used for THT, while reflow soldering is used for SMT. Both methods involve heating the solder to create a solid electrical connection between the components and the PCB.
Inspection and Quality Control
After assembly, PCBs undergo rigorous inspection to ensure they meet quality standards. Automated Optical Inspection (AOI) and X-ray inspection are commonly used techniques to detect any defects in solder joints or component placement.
Challenges and Considerations in PCB Fabrication
Handling High-Density Interconnects (HDI)
As electronics become more compact, handling high-density interconnects (HDI) in PCB manufacturing poses a challenge. HDI involves finer traces and smaller vias, requiring advanced fabrication techniques.
Managing Thermal Performance
Thermal management is crucial in PCB design, especially for high-power applications. Proper material selection and layout design can help dissipate heat effectively, preventing damage to the components.
Material Compatibility and Durability
Ensuring that all materials used in circuit board fabrication are compatible and durable is essential for long-term reliability. This includes selecting the right solder mask, substrate, and surface finish.
Balancing Cost and Efficiency
One of the biggest challenges in PCB fabrication is balancing cost and efficiency. While advanced techniques and materials can improve performance, they often come at a higher cost. Designers must find a balance that meets both performance requirements and budget constraints.
Innovations in PCB Fabrication
Flexible and Rigid-Flex PCBs
Flexible and rigid-flex PCBs are increasingly popular in applications where space is limited, or the PCB needs to bend. These innovations offer greater design flexibility and can be integrated into wearable devices, medical equipment, and more.
Use of Advanced Materials in Circuit Board Fabrication
The use of advanced materials, such as high-frequency laminates and thermally conductive substrates, is revolutionizing PCB design. These materials enable better performance in specialized applications like RF circuits and power electronics.
Automation in the Fabrication of PCB Process
Automation is becoming a key factor in improving the efficiency and accuracy of PCB fabrication. Automated machines can handle everything from drilling and plating to solder mask application and inspection, reducing the potential for human error.
Contact OurPCB
Understanding the steps in PCB manufacturing and assembly is crucial for producing high-quality PCBs. At OurPCB, we offer expert PCB manufacturing and assembly services tailored to meet your specific needs. Whether you’re dealing with complex high-density interconnects or need innovative materials for specialized applications, we can help. Our services ensure the success of your electronic products, from design and file preparation to final inspection and packaging. Contact us today to discuss how we can support your next PCB project.
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Had a run of PCBs created for our school. Used kicad Gerber files which matched perfectly with their online system . Couldn't believe how easy the process was. Fast turn around and the PCBs are of very high quality and price is very reasonable. Highly recommended and will return again.
I now use only OurPCB because of their simple instant online quotation and ordering system with PCB drag and drop files. The PCB quality is excellent, with excellent competitive prices to meet my PCB delivery urgency as required. Mark provides quick, excellent & friendly technical support. I recommend OurPCB to all Aussie manufacturers to support our last Aussie PCB company!
Been working with these guys for over 10 years now. The quality of their PCBs is first class with excellent delivery schedules. Any problems or 'extras' are handled promptly and efficiently. No hesitation in recommending them for any PCB manufacturing.
OurPCB have supplied our company with PCB circuit boards for the last five years. Firstly the quality is exceptional - Mark makes ordering circuit-boards easy. Where as in the past we have done the run around with component supply many times - Mark makes the process decisive and simple. The service is top notch. Highly recommended.
I push these guys on every front from superfine technology through to quick delivery - the quality and service is the best I've had anywhere. A truly great fab shop that is a pleasure to work with.