RAYMING PCB & ASSEMBLY

How to Panelise Small PCBs

Panelisation is the process of arranging multiple PCBs on a larger panel to be

manufactured simultaneously. This allows for reduced manufacturing costs per

board by scaling up production. Panelisation is especially useful for small PCBs,

where the material and handling costs of producing a single board would be

prohibitive.

In this guide, we will cover the key considerations and steps for effective

panelisation of small PCB designs.

Benefits of Panelisation

Panelising small PCBs offers several advantages:

Reduced Cost Per Board

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By manufacturing multiple boards together on a panel, you spread out the

setup, material, and handling costs. This reduces the cost per board. For small

volume production runs, it can make small PCBs cost effective to produce.

Easier Handling and Transportation

A panel containing multiple small PCBs is easier to handle, load, and transport

through the manufacturing process compared to individual tiny boards. The

panel provides a standard sized carrier that works with existing PCB assembly

equipment.

Optimised Board Packaging and Shipping

The panel itself can be used as a shipping and packaging format for finished

boards. Multiple boards pre-aligned on a panel simplify downstream packing

stages. No additional carriers or frames are required.

Improved Registration and Accuracy

Panelising boards can actually improve alignment accuracy compared to

processing individual boards. Keeping boards locked together on a panel

reduces registration errors from handling multiple tiny PCBs.

Panel Design Considerations

Effective PCB panelisation requires balancing many factors in the design:

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Board Size vs Panel Size

The relative sizes of the boards and panel are key considerations. Smaller

boards allow higher quantity per panel, but panels over a certain area become

challenging to handle and process. As a rule of thumb, aim for at least 8-10

small boards per panel.

Board Orientation and Spacing

Boards must be arranged to make best use of panel space while allowing

sufficient spacing for manufacturing tolerances and tooling. Both horizontal

and vertical orientations can work depending on the board dimensions.

Tooling Holes and Fiducials

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Tooling holes and fiducials on the panel perimeter are essential for accurate

alignment and registration during fabrication and assembly. Include multiple

fiducials distributed across the panel.

Breakaway Tabs and Rails

Breakaway tabs or rails connect boards together on the panel to maintain

alignment. Tabs must be designed to allow easy separation of boards after

manufacturing with no exposed copper or damage.

Board Outlines and Scoring

Each PCB outline should be clearly marked on the panel. Lines or scoring

indicates where boards can be separated after fabrication. Avoid designs

where critical features overlay the board outlines.

Panel Material and Thickness

The panel material (FR4, aluminium, etc) and thickness must be suitable for

supporting small PCBs through manufacture without damage while also

allowing cost effective processing of the larger panel size.

Steps for Panelisation

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Panelising PCB designs successfully involves attention at all stages:

1. Design and Layout

 Determine optimal board orientation and quantities per panel based on board
dimensions and target overall panel size
 Add breakaway tab features with clearance gaps to separate individual boards
 Include tooling holes, fiducials, and scoring lines on panel perimeter

2. Generate Panel Design

 Arrange required number of PCB designs onto panel area

 Add panel-level markings for tooling holes, fiducials, board outlines and breakaway tabs

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 Export panel design file

3. Verify Design Rules

 Check critical board dimensions are maintained (contours, keepouts, etc)

 Validate panel can be manufactured within capabilities and tolerances
 Review tab/rail clearance gaps and scoring depths

4. Fabrication and Assembly

 Produce panel using standard PCB manufacturing process flow

 Solder paste stencil for panel to support SMT assembly
 Run panel through pick and place and reflow process
 Assemble any through-hole components if required

5. Breakaway Boards

 Carefully separate individual PCBs from panel using breakaway tabs

 Avoid damage to boards or any components assembled on panel during separation
 Remove tabs cleanly without exposed glass fiber or conductive copper

Recommended Panel Design Rules

Incorporating the following design rules will result in panels that reliably

manufacture:

 Tooling holes minimum 4mm diameter placed ~200mm grid pattern

 Fiducials 1.5mm pads with 0.4mm holes distributed around perimeter -Tabs width
minimum 2mm connected by 1mm scoring
 Clearance gap of at least 0.1mm either side of scoring lines
 Avoid locating pads, traces, or vias under tab gaps or board perimeter

FAQs

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What size should my panel be?

Aim for the maximum panel size your PCB manufacturer supports, usually 18” x

24” (457mm x 610mm). This allows higher board quantity to maximise cost

savings.

How close can boards be spaced on a panel?

A minimum clearance gap of 0.2mm between boards is typical. Increase

spacing near panel edges or tightly packed areas for reliability.

How much material should tabs and rails leave to break away

cleanly?

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A 2mm tab width works well with 1mm deep scoring. This allows clean and

easy snap-off without exposed fibers or conductor damage.

When should boards be assembled while still in the panel?

If production volume is over ~25 boards, then it becomes worthwhile to

assembly boards in the panel for efficiency. This avoids repeated setup for

individual boards.

Is it possible to do functional testing of boards while on panel?

Yes, provide pogo-pin or test points access to all necessary board contacts

points. Program your test jig to probe each board position on the panel.

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