PCB assembly is a must for making any new device functional and productive. Engineers begin by building and testing a prototype on a breadboard or computer for that purpose. Prototypes are then assembled and tested on the layout. They make adjustments to the design depending on the results of their testing and then go into production with the finished product.

In PCB, two main methods are commonly in use. One is PCB Prototyping, and another one is standard PCB production. Both these methods are important and have their features. Moreover, developing a new PCB-based solution may be time consuming and challenging. Reducing the time and expense connected with the development process may considerably boost your future project’s probability of success. In this post, we will examine the benefits of starting your design verification with prototype PCBs and then the advantages of changing to standard-PCB production assembly after verifying your design.

In the past, engineers were restricted to designing PCBs with a maximum of two layers due to technology limitations. With advancements in technology, more than six layers are now the standard in multi-layer boards. Manufacturers prefer to employ committees with greater density and smaller SMD components to remain competitive.

Before mass-producing PCB designs, engineers must first demonstrate their notion via their design. The electronic industry refers to these concepts as prototypes throughout this design and manufacture phase. After that, engineers move towards standard PCB product assembly for mass production.

PCB Prototyping

Almost every electronic device includes a PCB to keep the electronic components in place and provide electrical linkages between them. The engineer’s job is to find the most cost-effective way to get the product to do what it’s supposed to do. Depending on the project, a Bill of Materials (BOM) for all the components that go into the final product may require the designer.

At this point, manufacturers require a PCB assembly manufacturer to negotiate the PCB materials and production process requirements. For the finished PCB to perform as planned, both parties must adhere to the process of Design for Manufacturing (DFM). For this, the manufacturer must provide the engineer with a small number of prototype boards that may be used to demonstrate the idea of their design.

It is common practice for engineers to utilize prototype PCBs to iron out design issues and enhance product performance. However, to go further, they must have PCBs that they can demonstrate to be successful. PCB prototypes are made here by the manufacturers.

Why is PCB prototyping done?

Creating PCBs in small batches from the same raw materials as the final boards is what Prototyping is all about. Fast yet restricted cycles are used during Prototyping to thoroughly inspect and test circuit boards. As a preliminary step before going into large-scale manufacturing, engineers use Prototyping to iron out any flaws in their circuit board design. Engineers like to start with a prototype PCB when developing new strategies.

PCB manufacturers take your design with the prototype service and swiftly create a small run of boards using basic materials, which they then send to you in only a few days. The objective is only to give you a feel of whether your design works or not and is worth it to make a complete production run. You may test the boards to find any design issue before making a significant PCB production investment based on that design.

In short, the PCB Prototyping service may assist you in finding such design modification needs early in the development cycle. Spot design problems in a limited number of prototype manufacturing run of your PCB board before scaling up production volume. Hence, it helps you improve your next design swiftly at a cheap cost.

Standard PCB Production Assembly

A greater level of functionality may be added to the design after the manufacturer has confirmed that the bare prototype boards operate correctly. They may make alterations to the fundamental method to improve efficiency. Finally, the last level of testing is done to avoid wasting time and money by removing probable faults.

There are more complex alternatives and more tight tolerances in standard PCB manufacturing. You may get a free DFM check from standard PCB to see if any issues might affect the final quality of your PCB, for example.

In standard PCB production assembly, PCB manufacturers are busy creating the boards you will utilize in your applications in mass production. This may take a little longer as we may employ different materials and more sophisticated fabrication procedures (e.g. multi-layer designs). However, it will typically still be faster than other PCB manufacturing services. So, if you are delighted with the small scale prototyping design and the work is excellent, the next step is moving towards the standard method of PCB.  

Why is Standard PCB Production Assembly Done?

In standard PCB production assembly, design problems are significantly less common, and it might save you some time to obtain the standard boards you need right now. If you are evaluating a new design, we strongly suggest employing a PCB prototype service. You will waste minimal time and test that your plan works before regular production, which might save you substantial time and money if you do find design defects. After the final selection, move towards the standard PCB assembly.

Other minor differences between PCB prototyping and Standard PCB production assembly are following:

1. In the PCB prototype, the Number of layers ranges from 1 to 8, while in standard PCB production assembly, the Number of layers ranges from 1 to 32.
2. In Prototyping, Order quantity can be 5pcs to 100pcs, while in a standard method, the order can be between 1pc to 10000+pcs.
3. The built time for Prototyping ( 2 to 7 days) is less as compared to the standard one ( i.e. 3 to 18 days)
4. In Prototyping, only FR4 material is used, while standard PCB assembly can be built with the help of FR4, Aluminum, Flex, Rogers, etc.
5. Free DFM checking is only possible in standard PCB production assembly, and you cannot have it in Prototyping.

Advantages and Disadvantages

We will see the pros and cons of each method one by one.

PCB Prototype Advantages

• Opportunity to execute a brief test run of your PCB design;
• Fast turnaround on your purchase;
• Identify any design issues immediately;
• You may update the design without having wasted an entire conventional manufacturing run;

PCB Prototype Disadvantages

• The boards’ tolerance is not like that of standard circuit boards;
• Verification is required before starting production.
• Limited board materials are allowed here
• Limited amount of layers for your boards as compare to standard one

Standard PCB Production Advantages

• There is no need to wait to acquire and test prototypes – you can get your boards into your applications much quicker
• You can order complicated panels — diverse substrate materials, several layers, etc.;
• You can order a big manufacturing run – save money with bulk pricing on larger purchases;

Standard PCB Production Disadvantages

• If you uncover a fault in your design, the whole manufacturing run might go to waste;
• There is no chance to change and enhance design before manufacturing;

Frequent asking questions

• What are the common types of PCB?
• PCB with a single layer (In terms of design and manufacturing, single-layer printed circuit boards are among the most straightforward.)
• The use of a two-layer PCB…
• PCB with many layers.
• HDI PCB (High-Density Interconnect)
• PCB with a High Frequency
• What is the goal of PCB prototypes?

Design concepts are tested to determine whether they function using PCB prototypes, early versions of finished goods. While most prototypes are designed to evaluate basic user functionality, engineers need working PCB prototypes to verify the design’s full functionality.

• How do you put together a PCB?

When a PCB has components attached to it, it is referred to as an assembled PCB, or PCBA for short. Traces are the copper wires that connect components and connections on a bare board.

• What is the purpose of printed circuit boards?

For both residential and industrial usage, electronic devices, the printed circuit board (PCB) is essential. Designing electrical circuits is made possible with the use of PCB design services. Additionally, it serves as structural support for the electrical components.

• How does Prototyping begin with?

Designing a prototype is the initial stage in this procedure. And bringing the entire assembly into the program allows you to see how it all fits together. After that you will figure the feasibility of prototyping.

Conclusion

Bothe the PCB prototyping and standard PCB production assembly are helpful and in great demand. Prototyping is ideal when you experiment with a new device, while the traditional method is ideal when everything is finalized and you want mass production.

Keep in mind that the amount of service appropriate for one board may not be adequate for the other due to the exclusivity of each board. Only time and practice can help you choose the best course of action in any given situation.