RAYMING PCB & ASSEMBLY

How to Estimate and Reduce PCB Assembly Cost?

Printed circuit board (PCB) assembly is the process of soldering electronic

components onto a PCB. It is one of the most expensive steps

in electronics manufacturing, so determining the assembly cost and

finding ways to reduce it is crucial for managing product budgets. This

guide will examine the key factors that influence PCB assembly pricing and

provide tips to lower costs without sacrificing quality.

Table of Contents

Factors That Determine PCB Assembly Cost

The main elements that impact the cost of assembling a PCB include:

Component Count and Complexity

The number of components to be mounted on the board is directly

proportional to assembly time and cost. More complex components like

BGAs or tiny passives also increase cost.

Board Size and Layers

Larger PCB sizes require longer assembly times. Multilayer boards often

need more complex assembly equipment too.

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

Soldering Process

The soldering technology used – wave, reflow, selective, manual – greatly

affects automation levels and throughput.

Testing Requirements

Testing steps like ICT, flying probe, AOI, X-ray increase time and cost but

reduce defects.

Location of Assembly

Labor rates, facility costs and overhead vary based on country/region of

assembly.

Production Volume

High volumes benefit from economies of scale and better machine

utilization.

Board Design

Ease of assembly and testability designed into the board can reduce

manufacturing costs.

We will now examine each of these factors in more detail and how design,

component selection and manufacturing decisions can optimize PCB

assembly costs.

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

Request PCB Manufacturing & Assembly Quote Now

How Component Factors Impact Cost

Component Count

The number of parts to be mounted on a PCB has the greatest influence

on assembly pricing. More components means longer assembly time,

which translates directly to higher cost. Assemblers generally estimate

cost based on component count ranges:

Component Count Range Relative C

<50 Low
50-300 Medium
>300 High

For example, boards with 250 components may be 2-3 times the cost to

assemble versus boards with 50 components.

To reduce cost, be disciplined about justifying every component on your

bill of materials (BOM). Consider cost reduction redesigns to eliminate

unnecessary parts.

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

Component Size and Pitch

Tiny surface mount devices (SMDs) or those with very fine pitch lead

spacing require more sophisticated pick-and-place machines and skilled

operators, increasing assembly cost. Larger components are faster to

process.

Compare the cost impact of these example component sizes:

Component Size/Pitch Rela

0402 resistor 0.4 x 0.2mm High
SOIC-14 package 6.5 x 5.2mm Low
BGA package 15 x 15mm, 0.8mm pitch Medium

When possible, choose chip components no smaller than 0603 or 0805

packages. Avoid ultra-fine pitch ICs < 0.4mm pitch if not essential.

BGA and Other Complex Components

Components that require special processing like ball grid arrays (BGAs),

connectors, or shields can increase assembly cost. The soldering process

required is more complex and rework or repair of these components is

also expensive.

Minimize use of BGAs to reduce assembly pricing. Consider alternate high

density component options like QFN packages where possible.

Connectors and Odd Shapes

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

Connectors, switches, buttons, and other odd-shaped components often

require manual assembly steps, driving up cost. Designs that rely heavily

on these specialty components can suffer cost and lead time impacts.

Reduce unnecessary connectors to lower cost. Consolidate multiple

connectors into unified designs when feasible.

Component Height Variations

Mixed surface mount technology combining tall components like

connectors or capacitors with low-profile SMDs make assembly more

difficult. The soldering process must accommodate parts with varying

standoff height.

Matching component heights within ~0.5mm helps streamline assembly.

Separating tall and short components into different board areas also

simplifies assembly process optimization.

How Board Factors Impact Cost

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

Board Area Size

PCB sizes under 20 sq. in. (130 cm2) are considered low cost. Boards over

50 sq. in. (320 cm2) or especially above 100 sq. in. (650 cm2) dramatically

raise assembly pricing.

Larger area sizes mean longer process times for solder paste printing,

component placement, reflow soldering, cleaning, inspection, etc. Large

boards may also require equipment upgrades to accommodate their

dimensions.

Downsizing PCB area has perhaps the greatest impact to reduce assembly

costs. Carefully analyze board layouts and component placement to

minimize area whenever possible.

Board Layer Count

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

Multilayer boards typically cost more than double layer boards to

assemble:

Layer Count Relative Cost

Double layer Low
4-6 layers Medium
8+ layers High

Via-in-pad designs required for multilayer boards complicate assembly.

And soldering defects are harder to detect on inner layers.

Design with cheaper double layer boards where possible. Minimize layer

count for low volume or cost-sensitive projects.

Fine Pitch Components

Assembling boards with many ultra-fine pitch components under 0.4 or

0.5mm requires specialized assembly processes that increase cost:

 High precision pick-and-place machines

 Advanced optical inspection

 Special X-ray inspection

 Tight process control for reflow parameters

Coarser component pitches above 0.65mm can use standard lower-cost

assembly lines. Avoid using extreme pitch ICs unless absolutely required.

High Component Density

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

PCBs with dense component placement and routing require smaller

solder pads, finer solder paste printing, higher accuracy pick-and-place

machines, and more advanced inspection. This forces use of more

expensive assembly techniques.

If possible, increase spacing between components and enlarge pad

geometries to simplify assembly requirements. Watch

component-to-component spacing on both sides of board.

Flexible or Rigid-Flex PCBs

Assembling PCBs built with flexible circuit substrates adds cost and

complexity versus standard rigid boards. Special carrier plates and

clamping may be needed during assembly to control warpage. And many

flex/rigid-flex boards require manual assembly steps.

Avoid flexible boards unless bending or flexing is functionally required.

Carefully design rigid sections on rigid-flex boards to maximize use of

pick-and-place assembly.

High Temperature Materials

Assembling boards that use polyimide, ceramic, and other high

temperature materials requires process adjustments from standard FR-4

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

epoxy boards. Special soldering profiles may be needed to ensure

materials are not overheated. And inspection requirements are tighter.

Utilize standard FR-4 materials wherever possible. Reserve high

temperature boards only for environments exceeding FR-4 ratings to

control cost.

Request PCB Manufacturing & Assembly Quote Now

How Assembly Process Impacts Cost

Soldering Method

The approach used to solder components influences equipment

utilization, quality, and throughput:

Method Description
Wave soldering Board passes over flowing wave of solder Low
Reflow soldering Solder paste reflowed in oven Med
Selective soldering Mini-wave targeted at joints Med
Manual soldering Hand soldering all joints Hig

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

Simpler methods like wave soldering provide the most cost-effective

assembly. But component parameters often dictate use of more advanced

reflow or selective techniques.

Inspection and Testing

Testing steps are added to assembly lines to screen defects but increase

total cost:

Testing Method Usage Rel

AOI Automated optical inspection Medium
ICT In-circuit test High
Flying probe Electrical continuity checking High
X-Ray Detects hidden solder defects High

Determine minimum testing needed to meet quality levels for your

product and application. Balance cost versus risk of escapes reaching

field.

Conformal Coating

Applying protective acrylic or urethane coating adds an extra production

step with increased costs. Adds ~10-20% to assembly pricing.

Only use conformal coating when environmental protection is truly

required since bare boards are cheaper. Consider selective coating of

sensitive areas only to reduce costs.

Cable and Wire Harness Assembly

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

Integrating external cables or wire harnesses with the PCB subassembly

increases complexity and cost. Manual wiring steps are often required.

Simplify cabling requirements if possible. Consider modular cable designs

that allow field connections to minimize wiring done during production

assembly.

Box and Enclosure Assembly

Populating PCBs into plastic or metal enclosures requires additional

process steps and tools versus bare board assembly. Automated

assembly is limited.

Defer high-cost box build steps until later stages of production to keep

initial assembly costs down. Consider purchasing pre-assembled

enclosures from specialist suppliers where feasible.

How Location Impacts PCB Assembly Pricing

Country and geographic region are major cost factors, mainly due to

differences in labor rates:

Location Typical Hourly Labor Rate Range

United States $40 – $150 per hour
Canada $35 – $85 per hour
Western Europe $30 – $50 per hour
Eastern Europe $15 – $35 per hour
China $10 – $25 per hour
Southeast Asia $6 – $15 per hour

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

Labor represents 50%+ of total assembly cost. So lower wage regions can

provide dramatic savings. However, also consider hidden costs like

shipping, travel, communications, quality, IP protection, etc.

Optimizing Designs to Reduce Assembly Costs

Simple choices in PCB layout and component selection can help

streamline assembly and lower cost:

 Use larger 1206 or 0805 SMT packages instead of tiny 0402

or 0201 when feasible

 Increase spacing between components to at least 8-10 mils or

0.20mm

 Avoid ultra-fine pitch ICs under 0.4mm. Use 0.5mm+ pitch

packages.

 Minimize tall parts adjacent to low-profile SMDs to reduce height

variations

 Utilize uniform component sizes/shapes instead of mixed specs

 Maximize use of double-sided assembly instead of multilayer

via-in-pad

 Consolidate connectors into standardized super-connectors

 Reduce overall PCB size and avoid over-large boards > 100 sq. in.

whenever possible

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

 Clearly separate and segregate SMT and through-hole component

regions

 Include board-level test points, fiducials, and other DFT features

 Apply solder mask cleanly without webbing between fine pitch pads

These simple design-for-assembly tips ensure your board can be

manufactured without specialized assembly processes that increase cost.

Request PCB Manufacturing & Assembly Quote Now

Strategies to Reduce PCB Assembly Costs

PCB

Assembly Control Board

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

In summary, here are the top tactics that can help minimize total assembly

expenses:

 Simplify designs – reduce parts counts, avoid complex components

like BGAs, minimize cabling or connectors unless essential

 Consolidate components – substitute multiple simple parts with

integrated multipurpose ICs whenever possible

 Standardize – use common footprints, uniform heights, consistent

placements across all boards

 Utilize cost-effective components – avoid exotic small or ultra-fine

pitch packages, go with mainstream SMT specs

 Design for assembly – allow generous spacing, avoid mixed

technology, design for easy inspection

 Minimize PCB footprint – critically evaluate all board dimensions to

reduce size and layers

 Standardize test requirements – balance defect detection versus

cost, avoid unnecessary testing

 Assess geographic options – use locations with optimal labor rates

and infrastructure

 Work with assembly experts – seek guidance from your EMS

provider during design process

PCB Assembly Cost Estimation Tools

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

Several free online calculators can provide ballpark assembly quotes

based on key parameters:

 PCB Assembly Quote Calculator

 MCL PCBA Cost Estimator

 PCB Assembly Cost Estimator

 PCBA Cost Estimator

 PCB Price Calculator

These self-service tools generate budgetary pricing in seconds. But consult

directly with assembly partners for detailed quotes on production

projects.

Getting Accurate Assembly Quotes

Follow this process when requesting PCB assembly quotes:

1. Send full manufacturing files – Gerbers, BOM, placement files, assembly

drawings

2. Define order details – quantity, lead time, target cost, quality

expectations

3. Select assembly provider – shot for 2-3 quotes from reputable EMS

companies

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

4. Review detailed proposal – analyze pricing breakdowns, projected

savings

5. Confirm final pricing – negotiate if needed, lock-in contract

Leverage assembly experts as early as possible in the design stage to

optimize decisions for low cost and high quality.

FQA about PCB Assembly Costs

What is the typical cost per assembled board?

Assembly prices range widely from $5 to $50+ per board depending on

complexity, order volume, and geography. Simpler boards in mid to high

volumes can reach $2 to $10.

What percentage of total product cost is assembly?

PCB assembly accounts for 30-60% of total product cost for many

electronics. The lowest BOM component costs may only represent 10% of

product price.

Can automated assembly reduce labor costs?

Yes, use of advanced pick-and-place and soldering automation can reduce

labor content for higher volume assemblies. But equipment costs are

high.

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

When does it make sense to use manual assembly?

For quick-turn prototyping or very low volume, manual assembly may cost

less than programming automation equipment. Even simple boards can

cost over $1000+ in setup fees.

How much does test and inspection impact assembly costs?

Testing can add 10-30% onto baseline assembly costs. Balance

requirements versus budget and production goals.

Conclusion

Determining PCB assembly costs and minimizing expenses takes careful

analysis across all aspects of component selection, board design,

manufacturing processes, geographic location, and product lifecycle

needs. Simple double-sided boards with mainstream SMT components in

mid to high volumes generally yield the most cost-effective assembly.

Seeking early guidance from EMS assembly partners can help designers

optimize all decisions for reduced manufacturing costs without sacrificing

quality or reliability.

Related Posts:

1. How to estimate Flex PCB Cost

2. How To Cut PCB Assembly Cost While Maintaining Quality

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 RAYMING PCB & ASSEMBLY

3. The Low Cost Industry Leading FT1 BGA Assembly

4. A guide to the Use of PCB Assembly Cost Calculator in Electronics

https://www.raypcb.com/what-affect-pcb-assembly-cost/

PCB Manufacturing & Assembly Services https://www.raypcb.com/