Maintaining the highest quality standards in circuit boards while also lowering PCB assembly costs remains an ongoing challenge for designers and manufacturers.

In this article, you will explore several advanced methods for cutting circuit board assembly expenses without affecting the reliability of the final product.

Key Points:

To reduce PCBA costs:

1. Clearly specify component placement and tolerance limits.
2. Prioritize Surface Mount Devices (SMDs), as they are suitable for automated assembly processes.
3. Select standardized passive component packages, such as 0201, 0402, 0603, and 0805.
4. Choose components that comply with RoHS environmental regulations.

Global and North American PCBA Market Forecast (2023-2029)

The PCB assembly market is projected to experience substantial growth. This expansion is fueled by rising demand from multiple industries, such as electronics, automotive, telecommunications, healthcare, and industrial machinery.

Size of the Global PCB Assembly Market

The global PCB assembly market is projected to expand from $96.75 billion in 2024 to $142.16 billion in 2029. It is anticipated to grow at a compound annual growth rate (CAGR) of 6.6% throughout the forecast period.

Source: Sierra Circuits’ market research analysis report, based on the annual reports of leading companies in the PCBA industry.

Size of the North American PCB Assembly Market

Source: Printed Circuit Board Association of America

Six Factors That Influence the Cost of PCB Assembly

9 Design Tips to Lower Circuit Board Assembly Costs

1. Choose Components with Standard Package Sizes to Streamline the Supply Chain

Component selection is a crucial step in printed circuit board design that can greatly influence total project cost.

Key Strategies for Efficient Part Selection to Minimize Assembly Costs

1. Opt for components with standard package sizes (e.g., 0201, 0402, 0603, and 0805) and established footprints to simplify the supply chain and decrease the requirement for custom PCB layouts.
   • Consult component datasheets and adhere to industry standards like IPC-735I when designing footprints. Accurate land patterns are essential to ensure dependable soldering and proper electrical performance.
   • Make sure pads are correctly sized and spaced to avoid misalignment and interference between nearby components.
   • Clearly define the part outline to prevent errors during automated assembly. Incorrect sizing may lead to manual corrections, which can raise production expenses.
2. Verify component availability and delivery times across multiple manufacturers and suppliers.
   • Components with extended lead times or limited stock can cause production delays and higher costs due to shortages.
   • Consider component lifecycle stages during the design process. If a key component becomes obsolete before production starts, it can disrupt timelines and require redesign efforts.

• Verify component availability before submitting design files for fabrication. This step is vital since certain parts may be unavailable at the time of ordering.

To prevent potential supply chain issues, Sierra Circuits provides a PCB component sourcing and stocking service known as customer-owned inventory. In this service, we manage your components from the quotation phase through to assembly.

3. Include alternate part numbers in your PCB bill of materials for components that may become unavailable. This facilitates quicker substitution approvals early in the process.
4. Remain flexible with component values where feasible and inform your manufacturer of this flexibility. This helps prevent minor value variations from affecting your design.
5. Account for component tolerances—such as those for resistors, capacitors, inductors, and diodes—during circuit design. Components with broader tolerances are generally more economical. Typical resistor tolerances include 0.1%, 1%, 5%, and 10% of their nominal value.
6. Avoid overspecified components, as they can make procurement more difficult and raise both cost and lead time.
7. Research alternative components on the market that may provide comparable or better performance at a lower cost. Performing a thorough component analysis is crucial for designers focused on cost efficiency.
8. Reduce the total number of components by integrating multi-functional circuits wherever possible.
9. Clearly label DNI (Do Not Install) components in your bill of materials. DNI is often used for larger or heavier parts, such as high-value electrolytic capacitors.
10. Always select RoHS-compliant parts. Non-compliant components, like BGAs, may require re-balling to meet RoHS standards, which increases assembly costs. Additionally, mixing RoHS and non-RoHS components on a board necessitates hybrid assembly, a more expensive process.
11. Confirm whether chosen components are available in bulk packaging. Manufacturers typically supply high-demand components on reels, which helps lower costs.

2. Ensure adequate spacing between components to avoid solder bridging

Positioning components too closely together can create challenges during soldering, inspection, and assembly due to restricted access or interference between parts.