How Much Does it Cost to Get a PCB Assembled?

When planning an electronics project, one of the most common questions is about the cost of PCB assembly. The short answer is: it depends. PCB assembly pricing varies widely based on multiple factors, with component costs being one of the most significant variables in the equation.

Component Costs: The Major Variable

One of the largest things to consider is the cost of components. There are some components that you can buy extremely cheap, while some integrated circuits (ICs) and Ball Grid Arrays (BGAs) can cost up to £8000. So it isn’t a clear-cut answer and depends entirely on the specification you need.

This enormous range in component pricing means that two seemingly similar PCBs could have vastly different assembly costs based solely on the components they require. A simple board with basic resistors, capacitors, and common ICs might cost just pounds to assemble, while a high-performance board with specialised processors or memory could cost thousands.

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Beyond Components: Other Cost Factors

While component costs often dominate the budget, several other factors influence your final PCB assembly price:

1. Board Complexity and Size

The physical characteristics of your PCB significantly impact assembly costs:

• Number of layers: More layers mean more complexity and higher costs
• Board dimensions: Larger boards require more materials and handling time
• Component density: Tightly packed components require more precise assembly techniques
• Special requirements: Requirements like impedance control or tight tolerances add to costs

2. Assembly Technology Requirements

Different components require different assembly methods:

• Surface Mount Technology (SMT): Generally more efficient for high-volume production
• Through-Hole Technology (THT): Often more labour-intensive and costly
• Mixed technology: Combining both SMT and THT adds complexity
• Special processes: Requirements like conformal coating or potting add costs

3. Volume and Production Runs

Economics of scale apply significantly to PCB assembly:

• Prototype quantities (1-10 units): Highest per-unit cost due to setup charges
• Small production runs (10-100 units): Lower per-unit costs as setup charges are distributed
• Medium production (100-1000 units): Further cost reductions through efficiency
• High-volume production (1000+ units): Lowest per-unit costs, often with dedicated production lines

4. Turnaround Time

Expedited assembly services come at a premium:

• Standard turnaround (10-15 working days): Most economical option
• Accelerated service (5-10 working days): Moderate price increase
• Express service (3-5 working days): Significant price increase
• Rush service (1-2 working days): Highest premium, sometimes doubling the cost

5. Testing Requirements

Different levels of testing affect the final cost:

• Basic testing (visual inspection, continuity): Minimal cost addition
• Functional testing: Moderate cost based on test complexity
• In-Circuit Testing (ICT): Higher cost, requiring test fixtures
• Burn-in testing: Significant cost for reliability verification

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Typical Cost Structures

PCB assembly services typically calculate costs using some combination of these elements:

1. Setup fee: One-time charge for programming pick-and-place machines and preparing for production
2. Component procurement fee: Handling charge for sourcing and managing inventory
3. Per-component placement charge: Cost per component placed on the board
4. Testing fees: Charges for performing required tests
5. Minimum order fees: Applied to small orders that fall below economic thresholds

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Controlling Assembly Costs

While some costs are unavoidable, several strategies can help manage PCB assembly expenses:

1. Design for manufacturability: Work with assembly partners early to optimize designs
2. Component selection: Choose readily available, standard components where possible
3. Volume planning: Consolidate orders into larger production runs when feasible
4. Flexible scheduling: Accept standard lead times rather than rush services
5. Component kitting: Consider supplying high-cost components yourself to avoid markup

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Getting an Accurate Quote

Because of the many variables involved, generic pricing charts rarely provide accurate estimates for PCB assembly. The most reliable approach is to submit your specific design for a detailed quote. Be prepared to provide:

• Gerber files and BOM (Bill of Materials)
• Assembly drawings
• Quantity requirements
• Turnaround time needs
• Testing requirements
• Any special considerations

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Conclusion

PCB assembly costs vary dramatically based on component selection, complexity, volume, and turnaround requirements. While it’s impossible to provide a one-size-fits-all price, understanding these factors helps you plan more effectively and avoid surprises.

At ABL Circuits, we provide transparent, detailed quotes based on your specific project requirements. Our team works with you to identify cost-saving opportunities without compromising quality or reliability.

Contact ABL Circuits today for a customised quote on your PCB assembly project. Our experts will help you navigate the variables and find the optimal balance between cost, quality, and performance for your specific needs.

Call ABL Circuits on 01462 414336 or visit www.ablcircuits.co.uk to request your personalised PCB assembly quote.

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