Prototype PCB Assembly FAQ
Why is prototype PCB assembly more expensive per board?
Prototype orders normally have higher unit costs because engineering review, sourcing, stencil preparation, machine programming, line setup, inspection, programming preparation, and testing are distributed across a small number of boards.
Many of these activities are still required whether the build contains 10 boards or a much larger production quantity.
As volume increases, these fixed or setup-related costs can be distributed across more units.
Is the manufacturing process different for prototype and production PCB assembly?
The core PCB assembly process is generally the same.
Both prototype and production boards may require material preparation, solder paste printing, SMT placement, reflow, inspection, through-hole assembly, programming, and testing.
However, production quantities may require different material planning, panelization, fixtures, process controls, inspection plans, automation, and production scheduling.
How many boards should we build for a prototype?
There is no fixed quantity for every project.
The required quantity depends on the engineering objective, product complexity, number of samples required, testing, certification, field evaluation, and the expected next development stage.
Can you quote prototype and production quantities at the same time?
Yes.
If future production quantities are known, you can request pricing for several quantities such as:
10 pcs / 100 pcs / 1,000 pcs / 10,000 pcs
Each quantity can be evaluated separately because component pricing, PCB fabrication, setup allocation, material purchasing, testing, and production planning may affect the unit cost.
Can you help if prototype components are difficult to source?
Yes.
We can review component availability, manufacturer lead time, lifecycle status, MOQ / SPQ, and potential second-source components.
Any proposed alternative component is submitted for customer review and approval before purchasing or assembly.
Can you help identify lower-cost alternative components before production?
Yes.
Prototype and NPI can be useful stages for reviewing BOM cost before the design and approved component list are finalized.
Standard passive components may have equivalent alternatives that provide different pricing or availability.
ICs, power devices, connectors, and other design-sensitive components require additional compatibility review.
Alternative components are not substituted without customer approval.
Can you modify the PCB layout if an alternative component is not pin-to-pin compatible?
Depending on the project and available design information, yes.
A replacement component may require changes to the footprint, placement, routing, or surrounding circuitry.
For design-sensitive components, schematic, electrical, thermal, firmware, and mechanical requirements may also need to be reviewed.
The engineering scope is evaluated before changes are made.
Can you program prototype boards?
Yes.
Programming requirements can be reviewed as part of the project. Depending on the product, support may include IC / MCU programming, firmware loading, and programming verification.
Can you build a functional test fixture for the prototype or later production?
Depending on the product and testing requirements, yes.
We can review customer-provided test procedures, test points, operating conditions, required measurements, communication interfaces, programming requirements, and pass/fail criteria.
Where required, a test fixture can be designed for the agreed testing process.
For some projects, it may be more appropriate to finalize or improve the fixture during NPI or pilot production after the product design becomes stable.
Can prototype PCB assembly transition into production?
Yes.
After prototype verification, the project can move through NPI or pilot production before repeat manufacturing.
Before production, the BOM, PCB revision, manufacturing documentation, programming, testing, approved components, and applicable process requirements should be confirmed.
