Lowering PCB Assembly Cost: A Guide
In the world of electronics, cost-efficient PCBA (Printed Circuit Board Assembly) design is crucial for businesses aiming to reduce expenses without compromising product integrity. This article explores various strategies for achieving cost efficiency and high-quality assembly in PCB design.
## Component Selection and Component Spacing
Optimising component selection and component spacing are key strategies for cost-efficient PCBA design. Choosing components that are widely available and less expensive, as well as standardising components across different designs, can help reduce inventory costs and simplify assembly. Ensuring adequate spacing between components reduces the risk of electrical shorts and improves overall reliability.
## Design for Assembly (DFA) Standards
Adhering to DFA standards plays a significant role in maintaining high product integrity while reducing assembly costs. Techniques such as via-in-pad protection, optimised pad geometries, and teardrop connections enhance solder paste deposition and reflow performance, making the assembly process more efficient.
## Design for Automation (DFA) and Manufacturing
Designing boards with components that are easily pickable and placable by automated machinery is essential for cost-efficient PCBA. Implementing effective trace routing methods, using SMDs for rapid and precise component placement, and considering the tolerances of components are all strategies that contribute to cost efficiency in the assembly process.
## Design for Manufacturability (DFM)
DFM ensures that the design is easy to manufacture by minimising unnecessary complexity and layers, which can reduce material and fabrication costs. Optimising material selection, using adhesive-less materials for flexible layers, and arranging boards on a panel efficiently using breakaway tabs are all strategies that contribute to cost efficiency in the manufacturing process.
By integrating these strategies, you can significantly reduce assembly costs while maintaining high product integrity in PCB design.
Recently, during a routine DFA check of a circuit board design provided by a customer, our PCB assembly engineers discovered a footprint mismatch. The mechanical dimensions of the component (FB115) in the Gerber did not match the datasheet. The Gerber files indicated a pad footprint for a 1005 package, whereas the actual component was a 0805 package. This inconsistency raised concerns about potential assembly issues and unnecessary expenses.
Implementing advanced techniques to reduce circuit board assembly costs while maintaining product integrity involves several strategies, including component selection, component spacing, DFA standards, and DFA. By following these guidelines, businesses can achieve cost efficiency and high-quality assembly in their PCBA designs.
Through the application of Component Sourcing strategies, such as selecting less expensive and widely available components, and optimizing component spacing to prevent electrical shorts, businesses can work towards cost-efficient Printed Circuit Board Assembly (PCBA) design. Additionally, by ensuring that designs adhere to Flying Probe Testing, technology advances can be leveraged to streamline the assembly process, reducing costs without compromising product integrity.
