Seeing your PCB design become a physical assembly for the first time is an exciting milestone. After hours of designing, reviewing and refining your circuit, it's finally time to find out whether everything works as intended. It's also the stage where many engineers start asking the same question: "What if it doesn't work?" The good news is that's exactly what the prototype stage is for. Very few products go from first prototype to full production without changes, and that's perfectly normal. Whether you're building your first PCB assembly or you've developed products for years, understanding the prototyping process can save both time and money. In this guide, we'll explain everything you need to know before ordering a PCBA prototype, from preparing your design files and requesting quotations to understanding costs and choosing the right Contract Electronics Manufacturer (CEM). What information do you need before requesting a quotation? There are several pieces of information you will need to give to your electronics manufacturer. It is best to ensure this is all correct prior to sending out an Request for Quote (RFQ) to ensure a quick and accurate quoting process. Bill of Materials (also known as the ‘BOM’) – A BOM is essentially the recipe for the product, most customers prefer to create this in a spreadsheet but if it is clear then you can use whatever programme you like. On the BOM, you will want to list the most important information regarding the build, as this will be used for two things; the purchasing and the manufacturing. You want to ensure it has information such as component type, component value, component size, component tolerance, reference designator and any other information that will help the manufacturer build your product correctly. Pick & Place data – This data is what tells the pick and place machines where each component goes on the PCB. Ideally you will want to include the following: X & Y coordinates, rotation, component code, component type. This data is usually given in an excel spreadsheet so the manufacturer can upload directly to their machine. If you are unable to obtain this data then do not worry, most machines can be set up manually, however the increase in set up time can result in an increase in cost. PCB Gerber Files – Gerber files are digital files used to manufacture printed circuit boards. The data shows the PCB manufacturer what the PCB should look like, and they use this to tell the machines in the factory how to build each physical layer. Gerber files will contain copper layers, solder mask, silkscreen, hole sizes and any other relevant features on the PCB. Assembly Drawing - If your PCB contains unusual components, polarity requirements or specific assembly notes, an assembly drawing helps ensure everything is built correctly. Final Manufacturing Details – During the prototype stage you might not be fussed about some of the details such as ident/silkscreen and solder mask colour, but it is still important to reference this to your supplier. PCB manufacturers will also panelise your PCBs onto production panels to maximise manufacturing efficiency. If you have specific panellisation requirements, be sure to discuss them before production begins. All of this information is essential to get right prior to sending an RFQ to your chosen manufacturer. If you spend more time preparing these things there will be fewer questions, making the quotation process easier for both you and your manufacturer. This part of the process is where we commonly see delays in prototype builds, we recommend you also read our previous blog post ‘7 Common Reasons PCBA Prototype Builds Get Delayed (And How to Avoid Them)’. Choosing the right CEM Now you have everything you need it is time to send all of this information off to a CEM (Contract Electronics Manufacturer). You might search Google and get overwhelmed by the results and you might just click on the first company that comes up but that isn’t the best strategy. There are lots of CEMs around the globe, you should choose a CEM who is the right fit for your product and your company. A few questions you should be asking when exploring options are: Does this CEM align with our company values? Does this CEM offer prototype work (some will specifically focus on full scale production) Can they match our product specifications, and do they have the required capabilities? Do they meet our requirements for quality? (E.g. ISO 9001, AS9100) Do we have any other requirements that the CEM needs to meet? (E.g. IATF 16949, NADCAP) Are their technicians IPC trained? Where are their manufacturing facilities located? Can they source obsolete or long lead-time components? (If required.) It is worth asking yourself these questions prior to approaching a CEM and only approaching relevant companies and to not assume every CEM has the same capabilities. What costs are involved? PCB tooling costs – PCB tooling preparation is an important part of the manufacturing process. During this stage, your Gerber files are reviewed by an engineer, who panellises the design (arranging it efficiently onto manufacturing panels) the data to manufacture the PCBs as efficiently as possible. This process also ensures the data is correctly outputted so the machines can read the data and there are no complications during manufacture. Stencil – During the assembly process a stencil is required to print the solder paste directly onto the PCB prior to placing the components. The stencil is made bespoke to your PCB design, and one stencil may be required for each populated side of the PCB. Materials – This includes the bare PCB and all electronic components such as resistors, capacitors, LEDs and connectors. Labour costs – Labour for both PCB manufacture and PCB assembly. This will include time to set up the machines; the actual time spent on manufacturing and machine changeover and programming time. Additional requirements – Sometimes you might have additional requirements such as conformal coating, an AS9102 FAIR or specific IPC testing (micro-sections, pull tests). It is important to remember these will all incur additional costs through the PCB manufacturer or the CEM. Why are PCBA prototypes expensive? The first prototype is often the most expensive version you'll build. But don’t let this scare you for future production orders, there are a few reasons why prototypes can be more expensive. Tooling costs – You will only incur these costs once on new products to that manufacturer. Stencils – Stencils can be a large cost however once your PCB design has been tested, changes made if necessary then you will only need to purchase your stencil once and these can last for thousands of prints. Minimum order quantities (MOQs) – Many component suppliers will have MOQs which makes things difficult and expensive when you are getting 1 prototype made and you have to order 50 of one part. The initial outlay will be expensive however the unit costs going forward will be much cheaper. Material Costs – PCB manufacturers often have a minimum production panel size. Even if your PCB only occupies a small area of that panel, you'll still be charged for the full panel, making low-volume prototypes more expensive per unit. Additional Costs – If you require an AS9102 FAIR, IPC testing etc. usually this requirement is for the first order only to confirm the part is manufactured correctly. Although these costs may seem daunting, many are one-off expenses that won't apply to future production runs. The prototype stage is important as it highlights to you and your team what works and what doesn’t, but this also means making design changes and remanufacturing PCBAs with all the above costs. At Advanced Assembly Solutions we encourage our customers to design their prototypes with this in mind. Is there a way to keep costs down without compromising on the quality? Yes, there is! You don’t always need to create multiple revisions of the same PCB which is costly. Instead, we can make changes to the same board by changing components, cutting PCB tracks and adding wire links where required. We pride ourselves on being flexible and allowing the customer to make changes during or after production. This method is quicker and more cost-effective. Once you're happy with the design, you can update the PCB layout and remanufacture the board incorporating those changes. We also recommend that you read our blog post on how to reduce PCBA prototype costs here, this goes more in-depth about other ways to reduce costs. RoHS compliance Every person working in the electronics industry should be aware of RoHS. When designing PCBs and selecting your components this is something to be aware of. If you are building a product that is lead-free, then the majority of components will be safe. However older components and technologies mainly prior to 2006 contained lead so this is something to be aware of. Whether you're building your first proof of concept or refining an existing design, having the right CEM can make the prototype stage faster, less stressful and ultimately more successful. If you'd like to discuss your project or get advice before requesting a quotation, we'd be happy to help.

Delays during the PCBA prototype stage can have a knock-on effect throughout an entire project, impacting development schedules, testing programmes and product launch dates. While some delays are unavoidable, many are caused by issues that can easily be prevented before production even begins. Whether it's missing manufacturing data, obsolete components or unclear assembly requirements, identifying these problems early can save both time and money. Based on our experience manufacturing PCBA prototypes, here are seven common reasons prototype builds get delayed—and how to avoid them. 1. Missing or Incorrect Manufacturing Data There are several types of data you supply to your electronic manufacturing partner: · Bill of Materials (BOM) · Pick and Place Data · PCB Gerber Files · PCB & PCBA drawings Ensuring the correct manufacturing data is supplied to your electronic manufacturing partner is essential. While some errors are easy to identify, others may only become apparent once production has started. Incorrect manufacturing data often means production has to stop while the issue is clarified. In the worst cases, assemblies can be built incorrectly, leading to costly rework or complete rebuilds. Depending on the issue, rework may be possible, but it should never be relied upon as a solution. Ensure all data is the correct revision and is checked prior to sending to prevent errors occurring during production. 2. Obsolete or Unavailable Components The world of components can be a minefield; Component prices fluctuate, lead times can change from next-day delivery to several months, and parts can become unavailable or obsolete with little notice. When this happens, you are then stuck trying to find suitable alternatives which increases the purchasing time and therefore delays the project, adding unnecessary stress. It is good practice to include component availability within your organisation's risk assessment and have a list of suitable alternative parts and suppliers. 3. Component Footprint or Package Mismatches Even when the correct manufacturer part number has been selected, problems can occur if the PCB footprint doesn't match the physical package of the component. For example, specifying an 0603 resistor while the PCB has been designed for an 0402 package. These issues are often only discovered during assembly preparation, resulting in delays while the design is reviewed or replacement parts are sourced. Carrying out a design review before releasing data and checking footprints against the component datasheets can help prevent these issues. 4. Design Changes and Revision Control During the prototype stage, design changes are common as issues are identified and improvements are made. However, if updated data isn't clearly revision controlled, there's a risk that obsolete drawings, Gerber files or BOMs could be used during production. This can delay production while the correct information is confirmed or, in the worst case, result in the wrong version being built. If materials have already been ordered or production has started, late design changes can also require components to be reordered or assemblies to be reworked. Maintaining clear revision control for all manufacturing data and stating the required revision on your purchase order helps ensure everyone is working from the same information. 5. Missing Specifications & Special Requirements Depending on your product, industry and customer you might have certain specifications or special requirements you need your supplier to follow such as: · Relevant IPC class (e.g. IPC-610 Class 3) · ITAR · Specific packaging requirements · Customer-specific specifications (also include a copy with your quote) · Specific process requirements · Tooling requirements It is important to specify these at the time of the quote so your supplier can give an accurate price and lead time and know if its within their capabilities. If these requirements aren't communicated from the outset, your manufacturer may be unable to meet them or may need to pause production while clarification is sought. If specs are obsolete, you may delay production whilst a new specification is given, the drawing is changed or granted a concession. To prevent these things happening, provide all information at the time of the quote to save delays. 6. Missing or Unclear Assembly Notes Assembly drawings often contain important instructions that aren't obvious from the CAD data alone. These might include component orientation requirements, selective soldering instructions, adhesive application, conformal coating, depanelisation methods or whether certain components should be fitted only after testing. If these requirements aren't communicated clearly before manufacture begins, production may be delayed while clarification is sought or, worse, the product may not be assembled as intended. Including clear assembly notes and discussing any unusual requirements during the quotation stage helps avoid unnecessary delays. 7. Incorrectly Supplied Free-Issue Materials Free-issue materials can be a great option for prototype builds, particularly when customers already hold stock or need to control component sourcing. However, like anything it does come with some risks, such as wrong parts supplied, wrong quantities or incorrectly labelled reels or trays. This will delay the manufacturing process or even put it on hold until you are able to send out more parts to your electronic manufacturing supplier. And of course this can result in extra postage fees. Although these risks exist, free-issue materials remain a valuable option when managed correctly. Taking the time to check part numbers, quantities and packaging before shipment can help avoid unnecessary delays. Prototype builds are designed to identify issues before full production begins, but many manufacturing delays can be avoided long before the first PCB enters the assembly line. Providing accurate data, maintaining good revision control and communicating requirements clearly allows your manufacturing partner to focus on building your product rather than resolving preventable problems. Spending a little extra time preparing your prototype package can save days—or even weeks—later in the project, helping you reach testing and production faster. Choosing an experienced manufacturing partner who reviews your data before production begins can also help identify potential issues before they become costly delays.

What is ESD? ESD stands for Electrostatic Discharge. It is the sudden transfer of electrical charge between two objects with different electrical potentials when they come into contact or are brought close together. For example, the shock you may feel after walking across a carpet and then touching a metal door handle. Why is ESD important in electronics? ESD can be a silent killer of electronic components because the discharge is often too small for humans to notice, yet still large enough to damage sensitive devices. Humans feel shocks above 3000 volts whereas electronic components can be damaged with less than 10 volts. The rapid discharge of static electricity can damage semiconductor junctions and, in severe cases, generate enough heat to cause permanent component failure. Bare PCBs (PCBs without components fitted) are generally far less susceptible to ESD damage than populated assemblies, so ESD concerns are usually focused on electronic components rather than the board itself. ESD damage is not always immediate. A component may appear to function normally after an ESD event but suffer hidden damage that reduces its lifespan or causes intermittent failures later in the field. Types of ESD Damage Catastrophic failure – component stops working immediately. Latent failure – component appears to work but has hidden damage that may cause future reliability issues. What can cause ESD? ESD can be caused by many different things. Handling - Static electricity from your body transfers directly into the device. Friction - Packaging, clothing and sliding against surfaces can all generate a static charge. Dust - Airborne particles and contamination can contribute to static charge generation and increase the risk of ESD events in poorly controlled environments. Tools - Everyday tools you might find on your workbench can be responsible for generating static charges. E.g. tape dispensers, plastic rulers, soldering irons, fans, printers. How can ESD be Prevented? There are lots of ways to prevent ESD, not all will be relevant for your workplace, you will need to analyse your work areas and choose the appropriate prevention methods. Handling - When handling ESD-sensitive devices you need to ensure you are grounded. There are various ways you can do this, the most common is by using wrist straps. When transporting it is important to use anti-static racks. Friction: Packaging - Anti-static packaging is widely available and can come in most forms e.g. vacuum seal bags, bubble wraps, boxes. You want to avoid the use of high static materials such as paper, foam and cardboard. Note: As long as the primary packaging is anti-static e.g. The boards are secure in anti-static bags, then they are safe to be packed in non-anti-static packaging. Customer requirements should always be checked first. Clothing - Anti-static clothing should be mandatory for all staff working on ESD-sensitive devices. Anti-static shoes are also great. Surfaces - Anti-static matting across workbenches is an easy way to prevent static charge build up when working on product. Dust - Daily cleaning with the use of air ionisers and air purifiers can all be used to help create dust free environments. Tools - Tools used within an ESD Protected Area (EPA) should be suitable for use around ESD-sensitive devices and form part of an ESD control programme compliant with IEC/BS EN 61340-5-1. Training - Regular training for staff ensures knowledge is kept up to date and helps reduce risks. ESD is an often invisible but significant threat to electronic assemblies. With the right training, equipment and processes, the risk can be greatly reduced, helping to improve product reliability and protect sensitive components throughout manufacturing and transportation. How we control ESD at Advanced Assembly Solutions At Advanced Assembly Solutions, we have over 35 years of experience manufacturing electronic assemblies and understand the risks ESD presents to sensitive components. Upon joining our company employees are given ESD training with refreshers completed annually. All employees and visitors must wear the provided anti-static coats and if applicable anti-static shoes. Before starting any work, we use the ESD wrist strap tester before starting at a ESD-safe workstation. For our customers, we invest in anti-static bubble wrap, packing film and 3 different types of anti-static bags. If needed, we can also ship in anti-static boxes although we highly encourage our customers to allow us to recycle and reuse our packaging.

Rising material costs, component shortages, and increased manufacturing expenses mean prototype development can quickly become a significant investment. The good news is that there are several ways to reduce PCB and PCBA prototype costs without compromising quality, reliability, or performance. Before looking at ways to reduce costs, it is helpful to understand why PCB and PCBA prototypes are often more expensive on a per-unit basis than production quantities. Why are PCB and PCBA prototypes more expensive? Minimum Order Quantities (MOQs) Minimum order quantities are fairly common with PCB materials and components, especially if the required material or part is uncommon or bespoke. These minimum purchase requirements can significantly increase the cost of prototype builds. Machine set up time & Programming time Depending on your product requirements, machine set up could take up a large part of the manufacturing time. For some bigger CEMs the time to prep isn’t worth the time to manufacture unless it’s confirmed the prototypes will be turning into large volume orders in the future. In some cases, the setup and programming costs can exceed the actual manufacturing cost of the prototype itself. Additional Prototype Expenses PCB tooling is required for all new PCB designs entering production. This process involves their engineering team panelising your data to fit as efficiently as possible on the required panel size and on their machines. It is during this process they will process any digital or physical artworks needed for manufacture. Stencils are another essential requirement for PCB assembly; without a stencil you wouldn’t be able to print the solder paste needed for the assembly process. For both tooling and stencils these will add additional costs however If the design is approved and moves into production without revision, both can typically be reused, eliminating this cost on future orders. FAIRs and other forms of testing, such as micro section analysis, may be required for first-time orders. Some customers and industries will require additional testing and a FAIR report to ensure compliance with relevant specifications and to ensure the product is performing as they hoped. This Is particularly important to get correct in the prototype stage. These will add additional costs but usually it is for the first batch. Understanding these cost drivers is the first step towards reducing prototype expenditure. By identifying where costs originate, you can make informed decisions that lower expenses without compromising quality or performance. 8 Ways to Reduce PCB and PCBA Prototype Costs Consider Free-issue components If materials or components have large minimum order quantities (MOQs), purchasing a larger quantity upfront can often reduce the overall cost per prototype. Buying a larger quantity will get you a cheaper unit price which reduces your prototype costs. Although the initial outlay can be more expensive, if you are sure the material and components are going to be used in the production batch once the prototype has been approved, this could be a good option. You can either purchase yourself and free issue to your manufacturer or ask the manufacturer to purchase for you and keep hold of the stock. Choose a specialist manufacturer Choosing a manufacturer that specialises in your type of product you are wanting such as a flex PCB makes all the difference. Their knowledge and expertise will deliver better DFM advice, reduce the risk of costly design mistakes and will offer faster troubleshooting. They will also have better purchasing power as they will have better existing relationships with the required material suppliers. Consider Multipanel Manufacturing It can be worth asking your PCB supplier about multipanel manufacturing. This can help reduce costs as your PCB is manufactured on the same mother panel as other PCBs. The cost is decreased because you’re sharing material costs and tooling costs and you’re not creating unnecessary wastage which is also great for the environment. Design for Manufacture (DFM) Having your design reviewed before production can identify unnecessary complexity, difficult component placements, or material choices that increase manufacturing costs. A DFM review early in the process can reduce both prototype costs and future production costs. Provide Accurate Pick-and-Place Data Pick-and-place data allows PCB assemblers to programme placement machines quickly and accurately. You can usually get your PCB designer to provide this data to give to your CEM. If you are not able to provide this data, do not worry this can be manually inputted onto the machine, however providing this data does save manufacturing time therefore saving you money. Select the right stencil type Many PCBA manufacturers will by default quote you for a tooled stainless-steel stencil, this is preferred because it fits on the manufacturer’s printer. There are other options such as a smaller stainless steel for bench printing, this is cheaper due to the size and reduced set up time. There are also acetate stencils for bench printing, this material is considerably cheaper than stainless steel but has a much shorter lifespan. If you are going through design changes, there isn’t much point ordering full-size stainless-steel stencils for a one-off then changing the design and making the stencil useless. Rework before re-manufacturing Don’t keep getting one-off boards manufactured with small design tweaks, ask for them to be reworked. There are many things that can be done to test design changes before permanently implementing them. Cut tracks, wire links and changing components can all be done after the PCB is assembled, letting you test new changes and saving both time and money. Once you have tested these changes then you can get a new PCB manufactured without all that extra cost in between. Ask your manufacturing partner for advice Don't hesitate to ask your manufacturing partner for advice. They manufacture every day and will have the knowledge to give you personalised advice on what is best for your product. Be honest and tell them you are wanting their advice on how to keep costs down and would like their expert opinions. They could offer alternative materials, components, solder paste, solder wire which have the same specifications to what you need but are cheaper. Manufacturers also can get better prices with certain suppliers so keep an open mind when given suggestions. Prototype costs can often seem high compared to production quantities, but understanding where those costs come from makes it easier to manage them effectively. By working closely with your manufacturing partner, providing complete design data, considering multipanel options, and exploring rework opportunities, you can significantly reduce prototype costs without sacrificing quality. If you're planning a new PCB or PCBA project and would like advice on cost-effective prototyping, the team at Advanced Assembly Solutions can help identify the most suitable manufacturing approach for your design.