Pointers On How To Lower The Cost Of PCB Prototype Manufacturing
I will give some pointers about avoiding costly mistakes while running prototype product and PCB manufacturing and how to minimize time to market for new electronic products.
Once you have finished your product and PCB design, you want to get started building prototypes before you commit to large production volume. Many design software packages such as PCB layout design software and industrial design software have simulation capabilities built in. Doing a simulation allows minimizing the number of design mistakes before the first prototype is built.
Choosing a modular design in which each module contains certain key functions will simplify the optimization of your prototype by allowing you to swap individual modules which do not meet your performance versus rebuilding the entire design. Swapping a single module will be fairly cost effective. In addition, performance characterization of modules will be faster than characterizing the whole design.
PCB components are often mounted manually during the prototype phase even though this method is time consuming. Subcontracting the prototype assembly offers higher quality. It can also save a lot of time.
When running small-quantity production runs, the production setup cost will typically dominate the overall prototype build cost. When looking for a subcontractor, it is best to select a vendor that specializes in prototype builds to minimize the expense. Prototype PCB manufacturers typically combine the circuit boards of several customers which effectively shares the setup cost amongst several customers. The drawback is that you will typically only be able to choose amongst several standard PCB material thicknesses and sizes.
Aside from selecting a supplier with low setup costs, picking a company that will also be able to handle your full-volume production runs minimizes mistakes since switching manufacturers has the chance of mistakes due to a particular supplier interpreting production design data differently. This way your design is already translated into the specific machine data which means little or no setup cost for your final production.
Some PCB manufacturers also can assist you during the design by offering in-house PCB design. If you are not very experienced in the design, you may want to consider picking such a vendor. Such a supplier can also much more easily and much more quickly resolve design-related issues.
One problem with small-quantity production runs is sourcing of PCB components. Most components vendors will charge ship fees and have minimum order quantity requirements for certain components. Also, dealing with a small quantity of components is a problem in case of surface mount assembly since components will be mounted from SMT feeders. Some manufacturers will stock standard SMT components that you can purchase from the vendor. This will save you the time of having to purchase these components individually. Also, you don’t have to worry about using up leftover components.
Choosing a manufacturer that is also able to do the final product assembly minimizes time to market by avoiding ship times between different vendors. Also, circuit boards that are found to be defective during the final testing can be repaired much more quickly. Finally, ensure that you are able to easily communicate with your supplier. This will help avoid costly mistakes and shorten production preparation times throughout all stages of PCB manufacture, PCB assembly and final product assembly.
You can find further details about PCB assembly and pcb layout by clicking at this link.
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